Door Arm Rest Week 8 Challenge

TREE STRUCTURE OF DOOR ARM REST

DRAFT ANALYSIS OF SOLID PART DOOR ARM REST AND VIEWS

DRAFT ANALYSIS OF MAIN TOOLING AXIS 1

FRONT

SIDE

TOP

ISO

DRAFT ANALYSIS OF MAIN TOOLING AXIS 2

FRONT

SIDE

TOP

ISO

DESIGN AND DRAFT ANALYSIS REPORT OF DOOR ARM REST USING CATIA V-5

OBJECTIVE: To design the Door Arm Rest using Surface Workbench and generate Drafting Analysis Report on the Class A and C using CATIA-V5.

DRAFT: When the molten plastic is completely ejected into the molded cavity and it is allowed to cool it tends to shrink to the core side of the mould and thus there deveolps a friction between the part [final output] and the mould. To overcome this drafting is required. It is required on all parts in the direction of mold movement in order to allow parts to release or eject from the mold properly.

Min draft required on final plastic component is 3 mm.

DRAFTING ANALYSIS:

Drafting Analysis is used to generate computational analysis of the component clearing the mould cavity without any damage [by friction] between the final component. It checks whether the Main Tooling Axis is correct or not thereby analysing the draft of the component. It shows whether all faces of the component has the required draft or not using value assigned colour codes [pic 2]. It further helps us to detect corrections in the earlier stage [i.e design] thereby preventing the cost and damage to the component.

Draft Analysis Icon

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Model Draft Analysis [2]

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FORMULATION OF MAIN TOOLING AXIS USING BI-SECTING METHOD

TOOLING AXIS: It is an Axis which indicates the direction in which the mould/cavity opens. It can also help in designing the component according to the drafting needs of an Industry.

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BISECTING METHOD:

Bisecting Method is used to generate main tooling axis by bisecting or dividing the two dummy tooling axis generated from intersection of planes.

However in Door Arm Rest we generate Two Main Tooling Axis in Z and Y direction for Draft analysis using Line Definition Tool by creating a line normal to the surfaces.

It can be created in both workbenchs.

At first the component is checked for any discontinuity in the line using two techniques. Namely

1. Join Definition

[4]

2. Boundary Tool

[5]

The above two images ensures that the component has no discontinuity in its line.

For Door Arm Rest we first extract the base and create a point where we want our Main Tooling Axis 1 to be. *[Creation of the point 1 [pic 6] assumes that if tooling axis is placed there it would clear all the components as it meets the required drafting standards of an Industry.] *

GENERATION OF TOOLING AXIS OF DOOR ARM REST

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For Door Arm Rest we first extract the base and create a point where we want our Main Tooling Axis 1 to be. *[Creation of the point 1 [pic 6] assumes that if tooling axis is placed there it would clear all the components as it meets the required drafting standards of an Industry.]

Main tooling Axis was generated using Line Definition Tool . [pic 7]

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Similarly Main Tooling Axis 2 was created using the same methodology except the direction was in Y direction inorder to get the Ribs cleared using Draft analysis. [pic 8]

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PUBLICATION

Before Publication make sure in the View Mode Customization dialogue Box [pic 9], Material box is checked which is available in the Mesh Subsection.

[9] [10]

DRAFT ANALYSIS REPORT OF DOOR ARM REST

At First, Compass Tool is used to position the co-ordinate plane into the main tooling axis of the component and locked using Lock Tool .

This compass tool is available in the drafting Dialogue Box along with Lock and Analysis under Running point Tool in the dispplay section of the dialogue box.

A Red pointer [pic 11] appears on the component when the cursor is moved over the component under drafting analysis. Left clicking on the mouse will give us Draft Analysis of the component.

1.DRAFT ANALYSIS OF CLASS-A SURFACE WITH TOOLING AXIS 1 IN Z DIRECTION

[11]

[12] [13]

[pic 12] - shows Running point Tool to check the draft on the face.

[pic 13] - shows Inverted Tooling Directing of the component and generation of Draft Analysis of the component.

Observation:

[pic 12] -The angle between the Class A surface and the Main Tooling Axis 1 in Z direction meets the requirement of Minimum drafting angle. To be specific the draft angle is > 3 [*Excluding the 3*] .But some red patches shown in pic 12 needs slight corection in Tooling Axis with respect to Class A surface.

The Image in pic 13 shows the Inverted demoulding direction. The Red patches are now more compared to what we saw in pic 12.

[pic 13] -Shows that the Inverted Tooling Axis and the faces that would clear are shown in Green Colour. Faces that are blue[inverted] in pic 12 can be cleared direction of inverted tooling Axis as shown.

The above draft analysis shows that the Class A- surface clears the minimum draft requirement of 3mm. Hence that surface can be proceed further to the Class C surface with thickness = 2.5mm

DRAFT ANALYSIS USING MAIN TOOLING AXIS 2 IN Y DIRECTION

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OBSERVATION

The Tooling Axis in Y direction is given to clear the Ribs [core] during de-moulding opeartion.

[pic 14] - Shows the faces that would clear the minimum drafting requirement. The faces that would clear are shown in Green colour. Blue colour shows that the faces that are inverted and that would likely to clear the minimum drafting requirement when the tooling axis is given in opposite direction or inverted.

[pic 15] - Shows that the Inverted Tooling Axis and the faces that would clear are shown in Green Colour. Faces that are blue[inverted] in pic 14 can be cleared direction of inverted tooling Axis as shown.

Still we can see red patches at the top. This indicates Draft Tool Axis angle manipulation to arrive at Minimum Draft Angle clearance for required faces.

COLOUR CODE IDENTIFICATION

RED	0 < A < 3
GREEN	0 < A > 3
BLUE	INVERTED

2.DRAFT ANALYSIS OF FINAL PLASTIC COMPONENT

USING MAIN TOOLING AXIS 1 [Z-DIRECTION]

` [16] [17] [18]

[pic 16] - shows Running point Tool to check the draft on the face.

Observation:

[pic 17] - Shows the faces that would clear in this tooling direction in Green Colour. And Blue Surfaces are inverted that indicates this would clear if the Tooling direction is reversed or inverted.

[pic 18] - Shows the inverted tooling direction and the faces that would clear are shown in Green Colour and again the faces that are in Blue colour indicates inverted faces that would clear if tooling direction is reversed or inverted.

The faces that are blue in colour in pic 17 are green in colour in pic 18 which indicates the min drafting requirement is cleared on inverting the tooling axis.

Some red patches on the ribs indicates that the requirement of correction in tooling axis angle in order to clear minimum drafting clearance [i.e 3mm].

USING MAIN TOOLING AXIS 2 [Y-DIRECTION]

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OBSERVATION

[pic 19] - Shows the faces that would clear in this tooling direction in Green Colour. And Blue Surfaces are inverted that indicates this would clear if the Tooling direction is reversed or inverted.

[pic 20] - Shows the inverted tooling direction and the faces that would clear are shown in Green Colour and again the faces that are in Blue colour indicates inverted faces that would clear if tooling direction is reversed or inverted.

The faces that are blue in colour in pic 19 are green in colour in pic 20 which indicates the min drafting requirement is cleared on inverting the tooling axis.

Some red patches indicates that the requirement of correction in tooling axis angle in order to clear minimum drafting clearance [i.e 3mm].

Conclusion:

The above drafting analysis shows that most of the faces of the component cleares minimum drafting requirement except some faces at the top which requires correction in Tooling Axis. The component can be further moved to manufacturing after incorporating required correction needed.