I am submit this report for reference to Mechanical Design Engineer (Automotive Plastic Trim). I have more than two of experience in the position of design engineer, during which I’ve become an expert in CAD software and the Plastic Design process. With this experience and expertise, as well as my drive to continually learn and develop my skills. I am a distinction Postgraduate Engineer with engineering plastic automotive knowledge. My skills on CATIA, GD&T, Nx 9 (Uni-Graphics), AutoCAD, Value Engineering and 6 SIGMA (DMADV) etc.

2. APPENDIXES
i PUBLICATIONS
• A Paper is Published on “Design Synthesis of Car Dashboard to Improve Interior Safety
Like Head Impact as Per Standard FMVSS 201/ECE 21” In International Journal for
Scientific Research & Development (IJSRD), May – 2019, ISSN (Online) 2321-0613
• A Paper is Published on “Concept Validation and Design Synthesis of Car Dashboard
as Per Plastic Trim Standard” In International Research Journal of Engineering and
Technology (IRJET), Volume: 06 Issue: 06 | June 2019, e-ISSN: 2395-0056, p-ISSN:
2395-0072
• A Paper is Published on “Six Sigma DMADV Approach for Conceptual Design
Synthesis of Car Dashboard” In International Research Journal of Engineering and
Technology (IRJET), Volume: 06 Issue: 06 | June 2019, e-ISSN: 2395-0056, p-ISSN:
2395-0072
• A Paper is Published and Presented on “Six Sigma Approach for Design Synthesis of
Car Dashboard to improve Interior Safety Like Head Impact and Knee as Per
Standard FMVSS 201/ECE 21’’ Multidisciplinary National Conference on
Management, Engineering & Sciences (MultiCon-2019), The presented papers published
in UGC Approved Journal “Research Journey International E-Research Journal”

3. v
CONTENT
CERTIFICATE............................................................................................................................................ I
ACKNOWLEDGEMENT..........................................................................................................................II
ABSTRACT.............................................................................................................................................. III
CONTENT.................................................................................................................................................. V
LIST OF FIGURES..................................................................................................................................................x
LIST OF TABLES.................................................................................................................................................xiii
LIST OF GRAPHS ...............................................................................................................................................xiv
1 INTRODUCTION.................................................................................................................................. 1
2 LITERATURE SURVEY....................................................................................................................... 5
3. THEORY..............................................................................................................................................11
3.1 WHY PLASTIC PRODUCTS FAIL?....................................................................................................................11
3.1.1 Poor specification and material selection – underestimation of the requirements .................................12
3.1.2 Design insufficiency......................................................................................................................................12
3.1.3 Processing issues...........................................................................................................................................12
3.1.4 Misuse of a product......................................................................................................................................12
3.2 DESIGNING A QUALITY PLASTIC PART FOR LIFE ............................................................................................13
3.2.1.Design ............................................................................................................................................................13
3.2.2.Tooling...........................................................................................................................................................16
3.2.3 Processing: Injection Molding.....................................................................................................................17
3.2.4 Assembly and Handling...............................................................................................................................17
3.2.5 Service ...........................................................................................................................................................18
3.2.6 End of Life ....................................................................................................................................................18
3.3 DESIGN CONSIDERATIONS ...........................................................................................................................19
3.3.1 Factors in Plastic Part Performance...........................................................................................................19
3.3.2 Part performance and life expectancy........................................................................................................19
3.3.3 Structural part design..................................................................................................................................20
3.3.4 Effect of time.................................................................................................................................................22
3.4 MANUFACTURING ASPECTS OF DESIGN .......................................................................................................22

4. vi
3.4.1 Part design considerations for molding......................................................................................................23
3.4.2 Mold filling....................................................................................................................................................24
3.4.3 Cooling ..........................................................................................................................................................25
3.4.4 Ejection..........................................................................................................................................................26
3.5 AFTER USE AND RECYCLING.........................................................................................................................26
3.5.1 Disassembly...................................................................................................................................................26
4 STANDARDS......................................................................................................................................28
4.1 FMVSS 201 ..................................................................................................................................................28
4.1.1 Scope..............................................................................................................................................................28
4.1.2 Impact Zone Marking Procedure ...............................................................................................................28
4.1.3 Test Procedure..............................................................................................................................................29
4.1.4 Judging Criteria ...........................................................................................................................................29
4.1.5 CAE ...............................................................................................................................................................29
4.2 ECE-R-21......................................................................................................................................................30
4.2.1 Scope..............................................................................................................................................................30
4.2.2 Impact Zone Marking Procedure ...............................................................................................................30
4.2.3 Test Procedure Ece R21...............................................................................................................................31
4.2.4 Judging Criteria ...........................................................................................................................................31
4.2.5 CAE ...............................................................................................................................................................32
4.3 PLASTIC GUIDELINE’S...................................................................................................................................32
4.3.1 Designing Parts for Up & Down Molding Helps Control Cost.................................................................32
4.3.2 Injection Molding Design Guidelines..........................................................................................................33
4.3.3 Uniform Wall................................................................................................................................................33
4.3.4 Radius............................................................................................................................................................36
4.3.5 Voids and Shrinkage ....................................................................................................................................38
4.3.6 Warpage........................................................................................................................................................39
4.3.7 Draft ..............................................................................................................................................................40
4.3.8 Ribs Design ...................................................................................................................................................41
4.3.9 Boss Design ...................................................................................................................................................44
5 METHODOLOGY................................................................................................................................46
5.1 DEFINE..................................................................................................................................................46
5.1.1 Identify Project CTQs..................................................................................................................................47
5.1.2 Define Process Map......................................................................................................................................54
5.1.3 Define Performance Standards ...................................................................................................................54
5.1.4 Identify Customer CTQs/ Customer Survey..............................................................................................55
5.2 MEASURE .............................................................................................................................................58
5.2.1 Input Requirement Checklist......................................................................................................................58
5.2.2 Quality Function Deployment .....................................................................................................................61

5. vii
5.3 ANALYZE...............................................................................................................................................68
5.3.1 Design Concepts (Competitive assessments (Benchmarking).................................................................68
5.3.2 Tradeoff Analysis .......................................................................................................................................74
5.4 DESIGN.................................................................................................................................................78
5.4.1 Engineering Analysis - Develop System & Subsystem Models...............................................................78
5.4.2 CTQ FLOWDOWN - For Each CTQ, Identify Design Parameters.......................................................80
5.5 VERIFY..................................................................................................................................................81
5.5.1 Error Proofing and Fixing...........................................................................................................................81
5.5.2 Validation......................................................................................................................................................82
6 MECHANICAL MODELING..............................................................................................................84
6.1 INTRODUCTION...........................................................................................................................................84
6.1.1 Draft Analysis...............................................................................................................................................85
6.1.2 Rules of Thumb for Design for Assembly ..................................................................................................86
6.2 CONCEPT TO WIREFRAME CAD MODELLING ................................................................................................87
6.3 UPDATE MODEL ACCORDING TO PLASTIC STANDARD GUIDELINES...............................................................88
Step 1 Tooling Line Generation ...........................................................................................................................88
Step 2 Modify Design for Draft & Tangency ......................................................................................................88
Step 3 Design with 100% Tangency.....................................................................................................................89
Step 4 Primary Draft Analysis .............................................................................................................................89
Step 5 SCALE X6 to length = 1270 mm Approx. ...............................................................................................90
Step 6 A Surface ....................................................................................................................................................90
Step 7 B Surface ....................................................................................................................................................91
Step 8 C Surface ....................................................................................................................................................91
Step 9 Closed Volume ...........................................................................................................................................92
Step 10 Part with Draft & Tangency ...................................................................................................................92
Step 11 Part with Draft & Tangency B side........................................................................................................93
Step 12 How to decide parting line ......................................................................................................................93
Step 13 Constraint.................................................................................................................................................94
Step 14 Model Without Ribs.................................................................................................................................96
Step 15 Model with Ribs .......................................................................................................................................97
Step 16 Draft Analysis...........................................................................................................................................97
7 MATERIAL SELECTION................................................................................................................ 100
7.1 RECENT RESEARCH IN AUTOMOTIVE PLASTIC INDUSTRY............................................................................100
7.1.1 The Nature of Plastic Materials ................................................................................................................100
7.1.2 Characteristics of plastic materials...........................................................................................................101
7.1.3 Technology activities and priorities..........................................................................................................101
7.2 MATERIAL SELECTED FOR DASHBOARD......................................................................................................106

6. viii
7.2.1 Materials Properties Table........................................................................................................................107
7.3 GRAPHS OF MATERIALS VS PROPERTY .......................................................................................................108
7.3.1 Young Modulus ..........................................................................................................................................108
7.3.2 Density.........................................................................................................................................................108
7.3.3 Yield Strength [Pa].....................................................................................................................................109
7.3.4 Poisson Ratio...............................................................................................................................................109
7.3.5 Thermal Expansion....................................................................................................................................110
7.3.6 Price.............................................................................................................................................................110
8 STRUCTURAL ANALYSIS............................................................................................................. 111
8.1 FORCE CALCULATION.................................................................................................................................111
8.2 CONSTRAINS .............................................................................................................................................112
8.3 STRUCTURAL ANALYSIS .............................................................................................................................117
8.3.1 Overall part analysis ..................................................................................................................................117
8.3.2 Analysis report Specific Nodewise ............................................................................................................119
8.4 ANALYSIS RESULTS ....................................................................................................................................122
9 HEAD IMPACT ANALYSIS............................................................................................................ 124
9.1 HEAD IMPACT ANALYSIS............................................................................................................................124
9.1.1 Mesh Generation:.......................................................................................................................................125
9.1.2 Contact Generation....................................................................................................................................127
9.1.3 Deck Preparation........................................................................................................................................127
9.1.4 Constrains ...................................................................................................................................................128
9.1.5 Post Processing ...........................................................................................................................................128
9.2 HIC FROM SOFTWARE (SIMULATION) ........................................................................................................129
9.3 ANALYSIS RESULT......................................................................................................................................130
9.3.1 Stress (Von-Mises) [=86pa].......................................................................................................................130
9.3.2 Displacement (mm) ....................................................................................................................................130
9.4 RESULT GRAPHS ........................................................................................................................................131
9.4.1 Energy (Kinetic, Internal, Total) ..............................................................................................................131
9.4.2 Internal Energy ..........................................................................................................................................131
9.4.3 Kinetic Energy............................................................................................................................................132
9.4.4 Hourglass Energy.......................................................................................................................................132
9.4.5 Spring and Damper Energy.......................................................................................................................133
9.4.6 Global Velocity ...........................................................................................................................................133
9.5 CALCULATIONS..........................................................................................................................................134

7. ix
10 RESULT........................................................................................................................................... 136
10.1 CONCEPTUAL DESIGN TO CAD..................................................................................................................136
10.2 CAD MODEL MODIFIED ACCORDING TO STANDARDS ...............................................................................137
10.3 MODIFICATION FOR DRAFT AND FEATURES .............................................................................................138
10.4 STRUCTURAL ANALYSIS RESULT ...............................................................................................................139
10.5 HEAD IMPACT ANALYSIS RESULT..............................................................................................................143
11 CONCLUSION ................................................................................................................................ 145
FUTURE SCOPE.................................................................................................................................. 146
REFERENCES....................................................................................................................................... 148
APPENDIXES....................................................................................................................................... 150
i PUBLICATIONS............................................................................................................................................150
ii Certificate..................................................................................................................................................151
iii REFERENCE IP PHOTOGRAPH ....................................................................................................................152
iv 3D PROTOTYPE (3D PRINTING)..................................................................................................................153

8. x
LIST OF FIGURES
Figure 3. 1 Distribution of causes of failures................................................................................ 12
Figure 3. 2. Life cycle of a plastic product. .................................................................................. 13
Figure 3. 3 Design guidelines for plastics..................................................................................... 14
Figure 3. 4 A mold with two cavities............................................................................................ 16
Figure 3. 5 Plastic part performances (Lampman, 2003).............................................................. 20
Figure 3. 6 Creep, stress relaxation and fatigue behavior of plastics. .......................................... 22
Figure 3. 7 Problems caused by thick sections and uneven wall thickness. ................................. 23
Figure 3. 8 Weld lines (DuPont, 2000)......................................................................................... 25
Figure 4. 1 : FMVSS 201 Head Impact Zone Marking ................................................................ 29
Figure 4. 2: FMVSS 201 Head Impact Exemption Zone.............................................................. 29
Figure 4. 3 : ECE R 21 Head Impact Zone Marking .................................................................... 31
Figure 4. 4 : ECE R 21 Head Impact Exemption Zone ................................................................ 31
Figure 4. 5 Proper wall thickness................................................................................................. 34
Figure 4. 6 Uniform wall thicknesses reduce/eliminate this problem. ........................................ 35
Figure 4. 7 Transition Wall Thickness.......................................................................................... 35
Figure 4. 8 Coring to element sinks.............................................................................................. 36
Figure 4. 9 Gusseting to reduce Warpage..................................................................................... 36
Figure 4. 10 Radius Recommendation.......................................................................................... 37
Figure 4. 11 Boss Design To Eliminate Sinks.............................................................................. 38
Figure 4. 12 Warpage.................................................................................................................... 40
Figure 4. 13 Draft Angles ............................................................................................................. 40
Figure 4. 14 Rib Design................................................................................................................ 42
Figure 4. 15 Rib Design................................................................................................................ 43
Figure 4. 16 Boss Design.............................................................................................................. 44
Figure 5. 1 CTQ’s Process............................................................................................................ 47
Figure 5. 2 Process map................................................................................................................ 54
Figure 5. 3 Cause and effect diagram : Customer satisfaction (Dashboard) ................................ 56
Figure 5. 4 Cause and effect diagram : Safety( Dashboard)........................................................ 57
Figure 5. 5 Cause and effect diagram: Design of Dashboard for DFM & DFA........................... 57
Figure 5. 6 Conceptual design ..................................................................................................... 68
Figure 5. 7 Benchmarking Conceptual Design 1......................................................................... 69
Figure 5. 8 Brainstorming Conceptual Design 2 ......................................................................... 70
Figure 5. 9 Establishing Concept Conceptual Design 3 .............................................................. 71
Figure 5. 10 Developing Alternatives to Concept Conceptual Design 4..................................... 72
Figure 5. 11 Concept Contradiction Conceptual Design 5 ........................................................... 73
Figure 5. 12 Conceptual CAD Design......................................................................................... 78

9. xi
Figure 5. 13 Dimension Taken from Actual Dashboard.............................................................. 79
Figure 5. 14 CTQ Flow down...................................................................................................... 81
Figure 6. 1 Draft analysis Concept Understanding STEP 1-5 ...................................................... 86
Figure 6. 2 Concept 3 Sketch........................................................................................................ 87
Figure 6. 3 Establishing the Primary Concept in CAD from Sketch............................................ 87
Figure 6. 4 Tooling Line Generation ............................................................................................ 88
Figure 6. 5 Modify Design for Draft & Tangency........................................................................ 88
Figure 6. 6 Design with 100% Tangency...................................................................................... 89
Figure 6. 7 Primary Draft Analysis............................................................................................... 89
Figure 6. 8 SCALE X6 to length = 1270 mm Approx.................................................................. 90
Figure 6. 9 A Surface.................................................................................................................... 90
Figure 6. 10 B Surface .................................................................................................................. 91
Figure 6. 11 C Surface .................................................................................................................. 91
Figure 6. 12 Closed Volume......................................................................................................... 92
Figure 6. 13 Part with Draft & Tangency ..................................................................................... 92
Figure 6. 14 Part with Draft & Tangency B side.......................................................................... 93
Figure 6. 15 How to decide parting line ....................................................................................... 93
Figure 6. 16 Doghouse.................................................................................................................. 94
Figure 6. 17 Four Way Locator..................................................................................................... 94
Figure 6. 18 Four Way Locator..................................................................................................... 95
Figure 6. 19 Screw Boss ............................................................................................................... 95
Figure 6. 20 Honey comb ribs....................................................................................................... 96
Figure 6. 21 Model Without Ribs ................................................................................................. 96
Figure 6. 22 Model Without Ribs ................................................................................................. 97
Figure 6. 23 Draft Analysis part A side........................................................................................ 97
Figure 6. 24 Draft Analysis part B side (No Ribs) ....................................................................... 98
Figure 6. 25 Draft Analysis part B side (with Ribs) ..................................................................... 98
Figure 6. 26 Draft Analysis of features......................................................................................... 99
Figure 7. 1 Interior of a typical vehicle...................................................................................... 102
Figure 7. 2 Body and Exterior of a typical vehicle (bumper, body panels and trims)............... 102
Figure 7. 3 Powertrain and chassis of a typical vehicle............................................................. 103
Figure 8. 1 Force Calculation..................................................................................................... 111
Figure 8. 2 Analysis type Static Analysis.................................................................................. 112
Figure 8. 3 Mesh Element type parabolic.................................................................................. 113
Figure 8. 4 Mesh Applied to Part............................................................................................... 113
Figure 8. 5 Applied Load........................................................................................................... 114

10. xii
Figure 8. 6 Constrains Locators.................................................................................................. 114
Figure 8. 7 Constrains 4-way Locators...................................................................................... 115
Figure 8. 8 Constrains Dog house.............................................................................................. 116
Figure 8. 9 Constrains 2-way Locators...................................................................................... 116
Figure 8. 10 Constrains Screw boss........................................................................................... 116
Figure 8. 11 Static Case Solution.1 - Von Mises stress (nodal values).1 .................................. 118
Figure 8. 12 Static Case Solution.1 - Translational displacement vector.1............................... 118
Figure 8. 13 Boundary Conditions............................................................................................. 119
Figure 9. 1 Meshing................................................................................................................... 126
Figure 9. 2 Contact Generation.................................................................................................. 127
Figure 9. 3 Desk Preparation ..................................................................................................... 127
Figure 9. 4 Constrains................................................................................................................ 128
Figure 9. 5 Post Processing Ls-Dyna Preparation ..................................................................... 128
Figure 9. 6 Post Processing and Analysis.................................................................................. 129
Figure 9. 7 Reference For Software Simulation ........................................................................ 129
Figure 9. 8 Stress (Von-Mises) Nodal ....................................................................................... 130
Figure 9. 9 Displacement........................................................................................................... 130
Figure 10. 1 Cad Model In Catia From Conceptual Design ...................................................... 136
Figure 10. 2 Cad Model Modified According To Standards ..................................................... 137
Figure 10. 3 Modification For Draft And Features.................................................................... 138
Figure 12. 1 Industry Revolution from 1.0 to 4.0...................................................................... 147

11. xiii
LIST OF TABLES
Table 3. 1 Examples of failures occurring in plastic parts............................................................ 20
Table 3. 2. Comparison of assembly methods for recycling and disassembly. ............................ 26
Table 3. 3. Requirements and influences relative to a corresponding life cycle stage. ................ 27
Table 5. 1 CTQ Importance Rating............................................................................................... 47
Table 5. 2 CTQ AND VOC Checklist .......................................................................................... 48
Table 5. 3 Project Charter............................................................................................................. 51
Table 5. 4 Team Charter .............................................................................................................. 52
Table 5. 5 Performance Standards ............................................................................................... 55
Table 5. 6 Input Requirement Checklist ...................................................................................... 59
Table 5. 7 QFD of Product Characteristics.................................................................................. 62
Table 5. 8 QFD of Product Characteristics Score......................................................................... 63
Table 5. 9 QFD of Product Design .............................................................................................. 64
Table 5. 10 QFD of Product Design Score .................................................................................. 65
Table 5. 11 QFD D Manufacturing.............................................................................................. 66
Table 5. 12 QFD D Manufacturing Score.................................................................................... 67
Table 5. 13 Tradeoff Analysis ..................................................................................................... 76
Table 7. 1 Plastic used by type and weight of an average car (Survey 2014-2025X) ............... 104
Table 7. 2 Materials Properties Table........................................................................................ 107
Table 8. 1 Element Quality For Structural Analysis.................................................................. 117
Table 8. 2 Structural analysis result with ribs and without ribs................................................. 123
Table 10. 1 Structural analysis result with ribs and without ribs............................................... 139

12. xiv
LIST OF GRAPHS
Graph 4. 1 : K Stress Concentration Factor Vs R Radius............................................................ 37
Graph 5. 1 QFD of Product Characteristics pareto...................................................................... 64
Graph 5. 2 QFD of Product Design Pareto .................................................................................. 66
Graph 5. 3 QFD D Manufacturing Pareto................................................................................... 67
Graph 7. 1 Plastic Vs Metal Used of an average car (Survey 2014-2025X) .............................. 105
Graph 7. 2 automotive Plastic market Volume (Survey 2014-2025X)....................................... 105
Graph 7. 3 Plastic Vs Metal Used of an average car (Survey 2018-2025X) .............................. 106
Graph 7. 4 Young Modulus (Pa) of materials............................................................................. 108
Graph 7. 5 Density of materials.................................................................................................. 108
Graph 7. 6 Yield Strength of materials....................................................................................... 109
Graph 7. 7 Poisson Ratio of materials ....................................................................................... 109
Graph 7. 8 Thermal Expansion of materials............................................................................... 110
Graph 7. 9 Price of materials ...................................................................................................... 110
Graph 9. 1 Energy (Kinetic, Internal, Total) Vs Time............................................................... 131
Graph 9. 2 Internal Energy Vs Time.......................................................................................... 131
Graph 9. 3 Kinetic Energy Vs Time .......................................................................................... 132
Graph 9. 4 Hourglass Energy Vs Time...................................................................................... 132
Graph 9. 5 Spring and Damper Energy Vs Time....................................................................... 133
Graph 9. 6 Velocity Vs Time..................................................................................................... 133
Graph 10. 1 Maximum Displacement No ribs VS With Ribs.................................................... 140
Graph 10. 2 Maximum Nodal Displacement No ribs VS with Ribs.......................................... 141
Graph 10. 3 Maximum Von Mises Stress No ribs Vs with Ribs ............................................... 141
Graph 10. 4 Nodal Von mises stress no ribs Vs with Ribs........................................................ 142
Graph 10. 5 Energy (Kinetic, Internal, Total) Vs Time............................................................. 143
Graph 10. 6 Velocity Vs Time................................................................................................... 144

13. 3D PROTOTYPE (3D PRINTING)