16. A-PILLER DESIGN USING MASTER SECTION IN CATIA.

OBJECTIVE: To create the A-Pillar's Plastic component from the given Class A Surface using the Master Section that is provided while following all the design rules.

BASIC STEPS:  

1. Check class A surface quality by using boundary command.

2. For B surface Offset the class A by 2.5mm. as thickness can be measured from master section

3. There were gaps on the Offset B surface the gaps were covered using Multi-section surface, swept command according to the need by extracting the that surface which is to be covered. Last join it using Join command. Here we have used sweep with simple guide and curve

4. To make Class C surface I have extracted Class A’s boundary one by one and swept it to 3mmApprox. Later I have Join the whole Class C. Also check angle as per draft norms

5. After that Join Class A and C and then took the intersection between these joined A and C with B surface then Split the AC with intersection and do the same for B. Later on join the surfaces A,B and C.

6. By using the close body command from the part workbench, I create a close body.

7. Further create a Dog House with help of Master Section. And create a Side core tooling axis for it. Later perform a Draft analysis on it. 

8. In the end perform a Draft analysis on the Part with the tooling axis.

INTRODUCTION:

Types of Pillars and their Importance in the Automotive Industry:-

 These pillars standing at the vertical or near-vertical (slightly inclined) position are structural supports for the car's roof and window areas. 

They are pretty important as they provide a strong foundation to install the glass (windscreens, rear, and side windows) of your car. Also, these are strong enough to hold the entire roof (even with roof racking to carry additional weights).

There are several pillars your car can have, and each has got a name. Pillars are named “A”, “B”, “C”, or “D” (in larger vehicles) if you move from the front to the rear end of your vehicle.

The number of pillars will vary from car to car.

For example, most sedans and hatchbacks will have three (A, B & C), whereas larger cars like SUVs will have all four (A, B, C & D) pillars.

Hardtop structures (often referred to as pillarless hardtops) will have only two (A & C) pillars.

ROLE OF THE A-PILLAR:

A-Pillar is located on either side of your car’s front window (or windshield).

They also hold the hinges of your front doors. A-pillars are generally made of steel alloys.

Besides being a supporting member, A-pillars are very crucial as far as safety is concerned. A-pillars usually carry a significant amount of load during a frontal collision or a rollover crash. So the larger the width or cross-section, the greater would be the strength but A-pillars always block the driver’s vision (create blind spots) to some extent that can be realized while driving. So, having that said, using thicker A-pillars can make the situation even worst. It might further lower the driver’s vision and raise a question about the vehicle’s and passenger’s safety.

Hence, the design of A-pillars must be optimized giving equal importance to both strength and the driver’s vision.

Firstly, we have to create the required Tooling-Axis for the given Class A Surface while meeting the requirements of the necessary Draft Angle & then perform the Draft-Analysis Operation on the Class A Surface itself.

After that, we have to create the required Class B & Class C Surfaces using which we have to make the Final Plastic Component and perform Draft Analysis on it.

MAIN REPORT:

Types of Surfaces and their Importance for an Automotive Plastic Designer:

• Class A Surface: Class A is an aesthetic surface with the highest quality finish. Most Class A Surfaces for an Automotive Component are made using 'Autodesk-Alias' based on the final Concept-Sketch. All Class A surfaces should have 'Curvature-Continuity', meaning the continuity between the surfaces should share the same boundary. It is taken as a reference by the Automotive Plastic Designer to create 'Class B' and 'Class C' Surfaces.

• Class B Surface: The Class B Surface resides below the Class A Surface at a certain thickness. It is created using Engineering Principles that consist of all the necessary features such as Ribs, Bosses, Snaps, etc. This surface isn't visible to the observer from the outside.

• Class C Surface: The Class C Surface is the surface created between the Class A and Class B surfaces to join them with each other.

STEP 1

       Now, we will begin by checking the State of Connectivity for the Class A Surface and ensure that there are no gaps between the surfaces as all the surfaces should be joined well together with each other and shouldn't consist of any discontinuities between them.

1. CLASS A INPUT

2. CHECK FOR BOUNDRY CONDITION AND VISUAL CLASS A INSPECTION WE GET NO IRREGULARITIES

3. OFFSET CLASS A BY 2.5MM AS THICKNESS OF MASTER-SECTION IS 2.5MM

4. USING GUIDE AND CURVE PERFORM SIMPLE SWEEP WITH CREATING NECESSARY BOUNDRY

5. JOIN OFFSET AND SWEEP TO GET COMLPETED CLASS B SURFACE

6. CREATE CLASS C USING CLASS A AS REFERENCE AND ITS BOUNDRY AS A CURVE

7. JOIN CLASS A AND CLASS C 

8. CHECK FOR ITS INTERSECTION WITH (A+C) AND CLASS B IF NOT EXTRAPOLATE CLASS B OR THAT AREA OF CLASS B WHICH IS NOT INTERSECTING

I have only extrapolated 1 edge which is shown above.

9. ONCE AGAIN CHECK IF (A+C) IS INTERSECTING WITH B TO GET IT TRIMMED WITH AND WE WILL GET A CLOSED SURFACE

10. CREATE A SOLID FROM CLOSED SURFACE

11. CREATE A MAIN TOOLING AXIS WITH HELP OF MASTER SECTION BY USING BISECTING METHOD

12. PERFORM A DRAFT ANALYSIS ON CLASS A, CLOSED SURFACE 

i. Class A

ii. Closed Surface

 12. Create A Dog-House taking input curves as reference

While creating 3-Point Plane we need to ISOLATE them to make them Free from constranied and Parent Children Relation is removed then their properties changed From EXPLICIT to COORDINTES to make constrained again.

TREE STRUCTURE

CATPart File is Attached Below