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

AIM :  DOOR TRIM CAT PART FOR DOG HOUSE . 

  OBJECTIVE : THE MAIN AIM OF THIS CHALLENGE IS TO CREATE A SOLID BODY OF DOOR TRIM LOWER WITH THE HELP OF THE CLOSED SURFACE METHOD BY USING THE  GENERATIVE SHAPE DESIGN WORK BENCH IN CATIA V5 . PERFORMING THE DRAFT ANALYSIS ON THE SOLID PART BODY OF THE DOOR TRIM . OVERVIEW : INITIALLY, WE NEED TO OFFSET THE GIVEN DOOR .

OVER VIEW :. 

    INITIALLY, WE NEED TO OFFSET THE GIVEN DOOR TRIM CLASS A SURFACE IN THE INNER DIRECTION TO THE REQUIED THICKNESS ( HERE THE THICKNESS IS 2.5MM) . AFTER THAT , WE NEED TO CLOSE THE PATCHES ON THE OFFSET SURFACE OF THE BUMPER, THE PATCHES ARE FORMED DUE TO THE  FILLETS ON THE CLASS A SURFACE. ONCE ALL THE PATCHES ARE CLOSED PROPERLY JOIN THEM TIGTHER TO MAKE A PROPER  CLASS B SURFACE  AND NOW SWEEP THE BOUNDARU OF THE CLASS A SURFACE  TO TRIM WITH THE CLASS B SURFACE TO MAKE A CLOSED BODY . BY USING THECLOSED BODY COMMAND IN THE PART WORKBENCH WE CAN GET THE SOLID BODY FROM THE CLOSED SURFACE OF THE DOOR TRIM NOW I CREATED THE HEAT STAKES AND LOCATORS BY CONSIDERING ALL THE DESIGN PARAMETERS. AFTER CREATING ALL THE B SIDE FEATURES ON THE SOLID PART BODY OF THE DOOR TRIM , I PERFORMED A DRAFT ANALYSIS FOR IT TO CHECK WHETHER ALL THE  SURFACE ARE  DARFTED  PROPERLY OR NOT ( THE DARDFT ANGLE FOR THE PLASTIC COMPONENT IS 0.5DEG TO 3. 0 DEG) 

TOOLING AXIS : 

   TO CREATE THE TOOLING AXIS , I EXTRACTED A SURFACE FROM CLASS A AND CREATED A POINT IN THE MIDDLE OF THE SURFACE BY USING THE  POINT COMMAND AND CREATED A LINE AT THAT POINT THROUGH THE Y -AXIS  NOW , I PERFORMED A DRAFT ANALYSIS CHECK FROM  THAT LINE WHETHER THE CRATED TOOLING AXIS IS IN THE CORRECT POSITIN OR NOT . IF IN THE DRAFT , ANALYSIS CHECK THE SURFACE HIGHLIGHTER WITH GREEN COLOUR ON BOTH SIDES OF THE SURFACE THE TOOLING  AXIS IS IN THE CORRECT POSITION AND DIRECTION .

 CLASS A SURFACE :

intersection method 

  create a new tooling axis by intersection method .

  create intersection along z and x directions . 

  take the first intersection and create lines which are coinciding the curves having  a draft angle . then  create bisecting line concerning the lines created.

   CLASS B SURFACE : 

      class b surface means the thickness of a part it is not  visible and is inside part . in other words , the class b surface is a surface below a certain thickness from the class -a suface . this is the surface that contains engineering aspects of a model . 

  crean ate offset surface of cin lass -a about 2.5mm inward direction . 

check for discontinuty and rework on the offset surface using extract , multi-extract, multi sections sufaces.

jion the surface and ensure the final class b surface created has no gaps .

 final b class surface :

CLASS -C SURFACE :  

   THE SURFACE THAT JIONS CLASS -A AND CLASS-B SURFACE  ARE THE SURAFACE IS CLASS -C SURFACE . CLASS C IS OFTEN SPECIFIED FOR INTERIOR SURFACE NOT READILY VISIBLE , SURFACE THAT WILL BE COVERED BY ANOTHER PART WHEN ASSEMBLED . 

 CREATE THE SWEEP CONCERNINGERENCE TO THE SURFACE AND TOOLING AXIS  MULTI EXTRACTINGTING THE CLASS -A BOUNDARY 

JION THE SWEEP SURFACE BY USING COMMAND LIKE  EXTRAPOLATE , TRMULTI SECTION SURFACE.

 FINALLY JION ALL THE SWEEP SURFACES AND ENSURE THE CONTINUITY OF THE CLASS -C SURFACE  

CREATING THE FINAL SURFACE

 FOR CREATING THE FINALS DOOR TRIM SURFACE , JOIN THE CLASS-A AND CLASS-C SURFACES TOGETHER.

THEN EXTRAPOLATE THE B SURGACE LITTLE BIT OUTWARD DIRECTION TO MAKE SURE THAT THERE WOULD NOT BE ANY GAP WHEN TRIMMING WITH THE JOINED SURFACE . 

THEN TRIM THE EXTRAPOLATED CLASS -B SURFACE  THE ITH JION SURFACE ( CLASS -A AND CLASS -C ) 

 MAKE A SOLID PARTB BODY USING THE CLOSE SURFACE COMMAND IN THE PART DESIGN WORK BENCH 

DOG HOUSE INTRUCTION : 

    DOG HOUSE IS AN ENGINEERING FEATURE USED IN PLASTIC DESIGN . DOG HOUSES ARE USED AS SUPPORT FEATURE. SOME TIMES OTHER ENGINEER FEATURE LIKE SNAPS , LOCATORS , AND SCREW BOSSES ARE MOUNTED ON THEM TO INCREASE THEIR STRENGTH .

 DOG HOUSES ARE SUBJECTED TO DRAFT ANALYSIS TO PREVENT BREAKAGE OF THE COMPONENT DURING EJECTION FROM THE MOULD CAVITY . DOG HOUSE AND OTHER ENGINEERING COMPONENTS ARE BUILT ON THE B - SURFACE .

   DOG HOUSE CREATION : 

             DOG HOUSES ARE DESIGNED TO AVOID SINK MARK CREATED ON THE CLASS -A SURFACE BY SCREW BOSSES AND TO SOLVE THE LENGTH ISSUES WHEN GINING SCREW BOSSES WHICH NEED TO BE ASSEMBLEDD TO OTHER COMPONENTS . 

  IT IS ALSO USEFUL WHEN PERPENDICULAR SCREW BOSSES ARE REQUIED ON THE PART TO THE TOOLING DIRECTION .

  C THICKNESS SHOULD BE 40% OF THE MAIN WALL THICKNESS T

   MINIMUM WIDTH OF THE DOG HOUSE IS 12 MM

   HEIGTH OF B SHOULD BE 3-6MM

   MINIMUM DRAFT FOR THE DO HOUSE DEGREES 5 DEGREES TO DIE DRAW.

PROCEDURE FOR CREATING THE DOG HOUSE :

  THE FIRST SETP IS TO CREATE A SIDE CORE AXIS 

  I HAVE CHOSEN THE NORMAL TO -THE -POINT METHOD FOR CREATING THE SIDE CORE TOOLING AXIS 

CREATE THE DOG HOUSE BY CREATING A POSITIONED SKETCH ON THE XY PLANE (OR)ZX PLANE . USING EXTRUDE OR SWEEP METHOD CREATE DOG HOUSEOUTER WALLS. 

NOW CLOSE THE TOP WALL USING THE MULTI -SECTION SURFACE COMMAND .

USING THICKEN COMMAND IN THE PART WORKBENCH , CREATE A SOLID PART OF THE DOG HOUSE.

 GIVE PROPER DRAFT ANGLES AND FILLETS BY CONSIDERING THE DESIGN RULES.

USING BOOLEAN OPERATION, UNION TRIM THE DO HOUSE BODY PART WITH THE DOOR TRIM COMPONENT . 

 DRAFT  ANALYSIS :.

    THE DRAFT ANALYSIS IS A COMMAND THAT ENABLES YOU TO DETECT IF THE PART YOU  TO DETECT IF THE PART YOU DRAFTED WIL BE EASILY REMOVED. THIS TYPE OF ANAALYSIS IS PERFORMED BASED ON COLOUR RANGES IDENTIFYING ZONES ON THE ANALYSED ELEMENT WHERE THE DEVIATION FROM THE  DRAFT    DIRECTION AT ANY POINT , CORRESPONDS TO SPECIFIED VALUES.

DRAFT ANALYSIS IS DONE AFTER DETERMINING THE TOOLOING AXIS , DRAFT ANALYSIS IS USED TO CHECK WHETHER THE MINIMUM DARFT (3 DEGREES) IS MAINTAINED OR NOT .

PROCEDURE  FOR PERFORMING THE DRAFT ANALYSIS  ARE AS FOLLOWS .

CHANGE THE VIEW MODE OF THE COMPONENT TO BE IN CUSTOMIZED PARAMETER MODE AND THEN SELECT THE SHADING MODE AS MATERIALLS.

THEN OPEN THE FEATURED DRAFT ANALYSIS TOOL FROM THE INSERT MENU. 

THEN CLICK ON THE USE THE COMPASS TO DEFINE THE CURRENT DRAFTING DIRECTION AND THEN DRAG AND ALIGN THE COMPASS ON THE TOOLING AXIS .

 THEN LOCK THE DRAFT DIRECTION AND PERFORM DRAFT ANALYSIS BY CLICKING ON THE COMPONENT .

 COLOUR RANGE REPRESENTATION 

  GREEN COLOUR - POSITIVE DRAFT 

  RED  COLOUR -ZERO DRAFT 

 BLUE COLOUR -  NEGATIVE DRAFT 

DRAFT ANALYSIS OF DOG HOUSE USING THE SIDE CORE AXIS:

 3D VIEW( FRONT , TOP , SIDE, ISOMETRIC VIEW )

 TREE  STRUCTURE :

CONCLUSION :

 I HAVE SUCCESSFULLY CREATED CLASS B AND C SURFACES USING THE GIVEN CLASS A SURFACE OF THE DOOR TRIM CREATED MAIN AND SIDE CORE TOOLING AXIS . PER FORMED DRAFT ANALYSIS THE FINAL COMPOMENT AND THE FINAL COMPONENT AND THE DOG HOUSE .