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

Aim:-

To create the Dog House for the Door Trim from the given Class-A surface, considering the design rules and thickness of the part as 2.5mm.

Fig.1: Door Trim with Dog House.

Tooling Axis:-

The direction with respect to the component in which the mould opens and closes is the tooling axis. Basically, it defines the direction in which the mould pulls apart.

Procedure to create the main tooling axis:-

For this model,

• First, the given Class-A surface was observed carefully from every direction and found that in Y-direction the Tooling Axis can be created.
  
  
  Fig.2: Given Class-A surface.
  
  
• Then, one bottom surface was extracted and a point was created in the middle of that surface.
  
  
  Fig.3: Point on the extracted surface.
  
  
• Then, a line was created passing through that point along Y-Axis.
• Then, draft analysis was done for the Class-A surface considering the line as tooling direction.
• When no error was found in the draft analysis the line was named as Tooling Axis.
• Hence, the Tooling Axis was created.
  
  
  Fig.4: Main Tooling Axis.

Procedure to create the side core tooling axis:-

For this model, the side core tooling axis is required for creating the dog house.

• First, a point is created on the main tooling axis.
• Then, a line was created perpendicular to the main tooling axis passing through that point in the direction of X-Axis.
• Hence, the Side Core Tooling Axis was created.
  
  
  Fig.5: Side Core Tooling Axis.

Draft Analysis:-

The draft analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft angle and the tooling direction provided. It also enables us to detect if the part will be easily removed from the mould or not. The ejection of the part from the mould depends on the draft angle.

Fig.6: Draft analysis of the given Class-A Surface.

Class-B Surface:-

Class-B Surface was created by offsetting the Class-A surface by 2.5 mm. Then the surface patches were solved.

Fig.7: Class-B Surface.

Class-C Surface:-

Class-C Surface was created using the boundary of the class-A surface and sweeping along the tooling axis direction. Then the edges of the sweeps were extrapolated and trimmed with each other.

Fig.8: Class-C Surface.

Combining A, B and C Surface:-

All three surfaces were combined by joining the Class-A and Class-C surfaces and trimming them with the Class-B Surface. At last, it was converted into the Solid Model by using the Close Surface command.

Fig.9: Joined Class-A, Class-B, and Class-C Surface.

Fig.10: Solid Model.

Dog House Design:-

Dog houses are designed to avoid sink marks created on the CLASS-A surface by screw bosses and to solve the length issues of screw bosses which need to be assembled with other components.
After making the solid model dog house was created following the dog house design rules.

Fig.11: Sketch for dog house.

Fig.12: Model with dog house.

Fig.13: Different views of the Door Trim.

Fig.14: Tree Structure for the Geometrical Sets and the Part Body of the Model.

Fig.15: Draft analysis of the Door Trim, considering the draft angle of 1.45 degrees.

Fig.16: Draft analysis of the Dog House, considering the draft angle of 1.45 degrees.

Conclusion:-

The Dog House was created for the Door Trim considering the design rules from the given Class-A surface. Also, the Tooling axis was created and perform the Draft analysis on both Class-A Surface and the solid model.