Door Arm Rest Week 8 Challenge

DOOR ARMREST BEZEL

AIM: To create the door armrest plastic component through the given Class-A surface and at the end perform the draft analysis on the model.

OBJECTIVES: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of them. All the sketches should be created under the geometrical set. Use of the close surface feature to make a solid body from the surface. To publish the tooling axis, class A, B and C surface.

PROCEDURE:

• First import the class A surface of the door armrest model in Catia v5.
• Check the connectivity of the Class A surface using the boundary option.
• Ensure that there is no gap between the two surfaces.

TOOLING AXIS:

• The tooling direction is used to find the direction in which the part is ejected out of the mould.
• The draft on the part should be positive to manufacture the part easily. The draft angle should be positive concerning the tooling direction.
• To create the tooling axis, we need the proper orientation or view that gives the correct features and draft available in the component. So here the component view from the Z direction gives the proper view for the tool to see the features present in the geometry.

SIDECORE TOOLING AXIS:

MAIN TOOLING AXIS:

CLASS B SURFACE:

• First, extract all the surfaces for the inclined portion of the base plate.
• Then these surfaces are first untrimmed to get the intersection for surfaces so that a replica can be created

• Then these surfaces are first untrimmed to get the intersection for surfaces so that a replica can be created.
• If the surface is not intersected, then extrapolate by point continuity propagation is used to make these surfaces have an intersection between them.
• Lastly, the surface trim is used to get the replica for the inclined surface.
• Now, the thickness of the final component is 2.5mm so this obtained surface is offset below by 2.5mm.
• Like that the rest of the region is extracted and trimmed to get the final B surface. Now, the fillets are assigned to the B class surface.
• This is to have a uniform thickness between the A and B classes. The whole component B surface is created in small parts, then joined using the trimmed option and then the final fillets are assigned.

CLASS C SURFACE:

• The C class surface will be created using the sweep command and for that, the boundary lines are obtained from the A-class surface.
• The curve part is then smooth by some value for ease in sweeping The curve part is then smooth by some value for ease in sweeping.
• Then, all boundary lines are sweep with a reference surface with an 87-degree angle since all surfaces must have a draft angle of 3 degrees.
• Also, the tooling axis is used as the direction of the sweep.

• Next, the surface is joined with the A-class to form a complete A and C surface. (note merging distance is kept at 0.003mm to avoid any gaps).
• Lastly, the A and C are trimmed with the B surface to get the final baseplate component. This obtained surface is then thickened in part design.

DRAFT ANALYSIS:

• To perform the draft analysis the view parameters are first set to material mode. Then go to Insert >> analysis >> feature draft analysis
• First, select the axis system and drag the axis system to align and coincide with the tooling axis and lock the orientation.
• This axis system defines the draft direction according to the tooling axis.
• Switch on the colour scale and set the minimum draft value. Here it is set to 3 degrees and it will be displayed in green colour. any draft angle below 3 degrees will be shown in red colour.
• Here, the compass direction is rotated to have the positive direction in the maximum portion of the part.
• Then the compass is locked in the orientation and a new tooling axis is created using the compass as the direction.
• Now select the running point tool to measure the draft angle at the various locations and then if all surfaces pass the draft analysis switch on the light effect that will show the component in green colour if the component has the required draft angle.
• The bin portion of the armrest has a negative draft because the model is not accurate and has some inappropriate surface that creates a problem in the final drafting.
• To overcome this problem, we clear this region properly in ejection.
• To publish the tooling axis and class A, Class B, And Class C surfaces first select them and then Go to menu bar > Tools > Publication.
• This will publish the tooling axis and class A, Class B and Class C surface which will be available in the Tree Structure

DRAFT ANALYSIS WITH SIDE CORE

DRAFT ANALYSIS WITH TOOLING AXIS

TREE STRUCTURE

FRONT VIEW

TOP VIEW

SIDE VIEW

ISOMETRIC VIEW

CONCLUSION:

Door Arm Rest plastic components using Class A surface have been successfully created and draft analyses have also been performed for the same.