Door Arm Rest Week 8 Challenge

Door Arm Rest Week - Challenge 8:

• Creating Tooling Axis by following OEM Standards.
• Creating Class B Surface and Class C Surface using given Class A Surface as an input.
• Making Solid Part of 2.5mm thickness.
• Preforming Draft Analysis for input and output.

Draft Analysis on a SWITCH BEZEL:

THEORIES OF DRAFT ANALYSIS:

• Draft is required on all parts in the direction of mold movement in order to allow parts ti release or eject from the mold properly.
• Draft is the angle in which the part is tapered to allow it to realese. As the part cools, it tends to want to shrink to the core side of the mold.
• Adding draft helps the part to release. Most parts or application require a minimum of 1/2 to 1 degree, however 3 degrees is widely accepted as the norm.

Draft:

• Draft analysis command which is used to detect the drafted part will be easily removable or not. This type of analysis is perfomed based on the colour variations.
• Tooling direction is the main tool considerations for plasctic part and for all mould parts. Because it defines the mould part to be manufacturable or not and the possibility of the plastic part coming out from the Core and Cavity part.

Draft Analysis Report:

Steps to follow or Approach for the Analysis:

Draft allows the part to release from the mould.

Draft angle is required for all the parts because of the mold movement in order to allow parts to release from mold properly.

CLASS A SURFACE:

• As a input Class A Surface can be in Distorted form or in Separate parts and we need to correct it.
• Either we can Join those parts together or Extract them and then Trim them together.
• Note: We as plastic design engineers are not allowed to make any changes in Class A Surface.

TOOLING AXIS CREATION:

• Injection moulding includes Core, Cavity, and Sliders to make a plastic product.
• Core, Cavity, and Slider move/side in a particular direction which is called Tooling Axis.
• Tooling axis can be made using either by Bisection method or Plane as a reference.

Fig structure tree for tooling axis

SLIDER TOOLING AXIS:

• Here a flat face is taken as reference and a point is created at the centre.
• A line is drawn from the point perpendicular to the face

CLASS B SURFACE CREATION:

• From the Class A surface , Extracted a set of Surface for to create the Class B surface by Using Extract Command From Below Image.
• We can use extract command for all surface we needed for to create Class B Surface and then Use the Untrim command to restore the surface up to the limit.
• The Surface at which features like Ribs, Screw boss, Dog house, etc. are made to support external mountings is called Class B Surface.
• Class B Surface is made by simply extracting A Surface, offset it to desired thickness and trimming them together.
• The Surface at which features like Ribs, Screw boss, Dog house, etc. are made to support external mountings is called Class B Surface.
• Class B Surface is made by simply extracting A Surface, offset it to desired thickness and trimming them together.

After the Untrim, use the Extrapolate command to Extend the edge upto 10mm.

• and then Finally use the trim command to cut the surfaces to get the desired output which we wanted.
• Offset the Trimmed Surface up to 2.5mm for the thickness we needed.
• Similarly, do the same procedure for all the remaining surface, need to get. we can clearly see in the Structure Tree.
• Now, Trim all the parts to get CLASS-B-SURFACE.
• Give fillets for all the requied edges. For the fillets add the thickness value, for example if the thickness is 5mm and the radius is 3mm, For Inward add the thickness value with radius and for the outward subtract the thickness value with radius to create a uniform thickness all around the shape.

I have seperated the b_surface into two section of first half and second half

 CLASS C -SURFACE:

• Class C surface is a connecting surface between Class A and Class B surface.
• Draft angle and Tooling direction are considered while making Class C Surface.
• White Surface indicates Class C Surface

• Use the boundary command to extract the edges from the Class A Surface. Similarly create boundaries for holes too.
• Use the Sweep command to get the Class C surface and this is the surface that joins Class A & Class B Surface.

Solid part:

Class A, Class B and Class C Surface are trimmed/ Joined together to form a Final Trim

Final trim is filled with a solid using the Close Surface command.

FINAL DRAFT ANALYSIS:

Finally the draft analysis has to be performed on the solid model that we get as a output and below image are attached. We achieved the requirement.

The green colour area shows that it satisfies the 3 - degree draft angle.

in below image the draft angle has been made for the output we had.

The draft is an angle provided to the part with respect to the tooling axis to reduce friction between Part and Mould.

Pocket Section is provided with a minimum of 3 Degrees of draft.

below images draft angle has been made from the given input.

Structure Tree

PUBLICATION:

CONCLUSION: 

• The main tooling axis and the side core tooling axis have been created successfully using the feature draft analysis tool.
• Final closed surface has been created by using the trim and join faeture.
• The part body has been created by using closed surface tool.
• Draft analysis has been successfully done on the part body.
• Thus the above challenge has been finished with the proper input and all the required documents are attached.