Door Arm Rest Week 8 Challenge

AIM: Creating the Door Arm Rest component through the given Class-A surface of 2.5 mm thickness with the tooling axis meeting the requirements of the draft angle and at the end performing the Draft analysis on the model.

PROCEDURE REQUIRED DRAFT ANALYSIS:

STEP 1: Ensure there is no gap between the two neighboring surfaces.

Operations>Boundary>definition>select component

STEP 2: Tooling Axis: The tooling axis is the direction in which mold or core and cavity are opened.

We have to check all possible tooling directions in all three axes. When we are deciding the tooling axis we have to make sure that all the faces should be visible to that tooling axis, no face should be hidden.

For this component, the Z-axis will be the best tooling axis as we can see all the faces of the component and can be cleared in the x and y axis direction.

STEP 3: To make tolling axis for this model we have to follow the following steps

• Create a point on the curve of the circular portion.

• Create another point on the same curve of the circular portion.

• Create a Mid Point through both points.

• We can see a midpoint as below

STEP 4: Pace the axis system on that point.

STEP 5 :Sketch for tooling axis along X direction.

STEP 6: Sketch for tooling axis along the Y direction.

STEP 7: Bisect tooling axis X and Y to get the Component tooling axis.

STEP 8: Rename, change color and give thickness to the tooling axis so that it can be easily identified.

STEP 9: Publish Tooling Axis and Door Arm Rest Component.

Select this two in model tree>Toolbar>tools>publication>ok

PROCEDURE FOR DESIGN:

STEP 1: Extracting Surfaces from the base of the door armrest.

• Extract the surface
• Untrim that extracted surface
• Trimming surface.
• Offset it inside to 2.5 mm

STEP 2: Extracting Surfaces from walls of door armrest.

STEP 3: Extracting Surfaces from the first half surface of door armrest.

STEP 4: Extracting Surfaces from the second half surface of door armrest.

STEP 5: Extracting Surfaces from a Filleted portion of the component.

• Sketch

STEP 6: Sweeping Fillet Portion

• Multiple extract edges of the C surface filleted portion.
• Smooth the curve of multiple extracted lines.
• Sweep the sketched line along a smooth curve.
• Offset it to 2.5 mm below.

STEP 7: Trimming and giving edges radius in final trim.

STEP 8: Trimming first half, Second Half, and Sweep portion.

• First Half B surface of door armrest component

• Second Half B surface of door armrest component

• Sweep Portion of door armrest.

• Trimming all three B surfaces.

• Give outward and inward fillet radius where both half bodies are joining.

STEP 9: Extracting Sweeps from all the boundaries of A surfaces.

• Multiple extracting edges of A surfaces.
• Smoothing the curve of multiple extracted lines.
• Sweeping smooth curve with sweep with direction panel.
• Extrapolating corner of the edges.
• Trimming it in the desired output.
• Joining all sweeps together.

STEP 10: Join the final trim (swept surfaces) and A surface.

STEP 11: Trim C surface and B surface to get thicken part.

• We can see the thicken C surface after trimming as below -

STEP 12: Switch to Part Design Workbench, Define Part body to make Door Arm Rest C Surface into a solid component by the surface panel.

PROCEDURE TO CHECK DRAFT ANALYSIS: Check draft analysis on the final part body.

STEP 1: Changing view mode to the material.

View mode>view mode customisation>tick material>ok

STEP 2: Calling Draft Analysis.

Toolbar>Insert>Analysis>Feature Draft Analysis

STEP 3:

• Drag the compass from the draft analysis box on the tooling axis and place it properly.
• Click on locks so the compass will get locked to the tooling axis.
• Click anywhere on the component.
• Click OK.
• Analysis of the color of the failing and passing surfaces.

If a component is showing in a Green color that means our component is ready for manufacture.

NOTE: If we find zero degree or negative degree filing color, we can fix it by changing the draft angle, sweep direction, modifying properly tooling axis, etc.

• Draft Analysis along tooling axis

LEARNINGS :

• Extracting tooling axis by sketch.
• Inserting Axis system and Publication
• Extract, Multiple Extract, Untrim, Extrapolate, Offset, Trim, Joining the surfaces.
• Giving Fillet radius to inside and outside Offset surfaces.
• Split and Blend Surfaces.
• Extracting Tangential Boundary.
• Smoothing Boundary.
• Sweep with a direction and surface panel.
• Joining A and C surface and trimming it from B surface to get the required thicken body.
• Draft Analysis and fixing errors.
• Concept of Sliders.