Week 10 - Challenge 2- Attachment Feature Creation (Dog House)

DOOR TRIM DESIGN

AIM

To create the DOOR TRIM plastic component from the given Class A Surface as an input.

CLASS A SURFACE GIVEN AS INPUT

There are following steps, which have to perform by using Class A Surface:-

1. First understanding the CLASS A SURFACE.
2. Create Axis system.
3. Than creating the TOOLING AXIS AND SIDE CORE TOOLING AXIS.
4. Draft analysis 1 for CLASS A SURFACE.
5. Creating geometrical sets for CLASS B SURFACE.
6. Creating CLASS C SURFACE using boundary and sweep command.
7. FINAL TRIM to get Final Surface.
8. CREATE DOG HOUSE DESIGN
9. Than go to PART DESIGN to get Close Surface Body.
10. Draft analysis 2 for CLOSE SURFACE BODY.

1. First understanding the CLASS A SURFACE.

• Class A Surface is given as an input for product design.
• Class A Surface is thickened by using engineering features.
• The part which is obtaining after Class A Surface get thickened are use for manufacturing in real time application.
• The Boundary Condition of Class A Surface must be checked.

2. CREATE AXIS SYSTEM

3. CREATING THE TOOLING AXIS

• From Class A Surface, we have to form TOOLING AXIS.
• The point where the component get molded from injection molding.
• On that point, create POINT first using EXTRACT surface.
• On that point, using point direction to form tooling axis.
• Tooling Axis is perpendicular to axis system.
• Side core tooling axis is horizontal to axis system.

4. DRAFT ANALYSIS 1 FOR CLASS A SURFACE

• Draft Analysis technique is used to analyse the product which we design is manufacturable and prevent the part being parallel to the direction of mold opening.
• The product can not be manufacturable, if it has 90° profile, which is parallel to the TOOLING AXIS.
• A small draft angle is applied in order to remove the component from the mold.
• No part is manufacture without the draft angle.

DRAFT ANALYSIS FOR CLASS A SURFACE (isometric , side view , top view, bottom view)

1. The green colour represent the draft angle is upto 0.5°.
2. The red colour represent the draft angle is 0°.
3. The blue colour represent the draft angle is in negative side.

5. Creating geometrical sets for CLASS B SURFACE

• THICKNESS 2.5 mm is given as input.
• The CLASS B SURFACE is obtained from CLASS A SURFACE on giving offset with thickness 2.5 mm.
• During offset, some flaws shows so this flaws are now recreated by using EXTRACT COMMAND .
• And complete all patches one by one where flaws shown.
• And after completing all patches then use fillet to get proper fillet using thickness properties.

EDGE FILLET CALCULATION

CIRCLE 1

CIRCLE 2

THE OFFSET VALUE FOR FILLET SIZE :-

1. THICKNESS + RADIUS = OFFSET INSIDE THE CLASS A
2. THICKNESS - RADIUS = OFFSET OUTSIDE THE CLASS A

6. CREATING CLASS C COMPONENT

• The CLASS C SURFACE is the final output obtained from the CLASS A and CLASS B Surface.
• Using boundary of CLASS A SURFACE and sweep the boundary with draft value 3°
• The CLASS C SURFACE has the thickness 2.5 mm and draft value as per requirement provided.
• The CLASS A and CLASS C SURFACE are JOIN and TRIM with CLASS B SURFACE to form the final DOOR TRIM SURFACE

7. FINAL TRIM to get Final Surface.

CLASS A + CLASS B + CLASS C = FINAL DOOR TRIM

8. CREATE DOG HOUSE DESIGN

Create the Dog House for the Door Trim considering the design rules mentioned in the video. Consider the thickness of the part to be 2.5 mm.

"C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• The height of ( B ) should be between 3.0 – 6.0 mm

9. Than go to PART DESIGN to get Close Surface Body.

10. Draft analysis 2 for CLOSE SURFACE BODY.

TREE STRUCTURE