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

AIM: 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.

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<!-- [if !supportLists]-->·        <!--[endif]-->Doghouse wall thickness at the intersection of the part wall (C) should be 40% or less than the main wall stock (T). 

<!-- [if !supportLists]-->·        <!--[endif]-->The height of (B) should be between 3.0 – 6.0 mm 

1. Tooling axis creation:

      The first step is to observe the given class-A surface deeply and we can say the larger flat area which is perpendicular to the Tooling axis. So, by considering this thing for this class-A surface tooling direction will be in the Y-direction. so, we create the point on the flat surface as shown in the figure.

Then create a line perpendicular to the flat surface through that point.

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 2. DRAFT ANALYSIS OF CLASS A SURFACE

                         The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis 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.

• Before going to drat analysis go to customized view parameter >under mesh > check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compass to define the draft direction.
• In the colour scale change the draft angle to 3 degrees.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.
• If the whole surface is green then angle given to tooling axis is correct and the part will be manufacturable along that direction.

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3. CREATING CLASS B SURFACE

Extract the surfaces from the class A using multiple extract and untrim them. Use Extrapolate to make sure that all the untrims are properly intersected to trim and offset the surfaces to 2.5 mm to create the thickness. Trim the extra surfaces using trim command. Insert them into new geometrical set and name it with respective part names. Apply fillets to the model after creating the entire surface. If the edges are outside the fillet value will be added to the thickness of the component and if the edges are inside, the fillet value will be subtracted from the thickness of the component, for instance the thickness of the component Is 2.5 mm the fillet value is 15mm so the outside portion value should be 17.5 mm and inner edges should be filleted 12.5 mm to get uniform thickness. Perform trims one at a time so that it will be clear to understand.

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4. Class C Surface:

• Unhide the A Surface to Take a boundary as a reference to make C surface.
• Go to sweep line-> with Reference Surface 03-degree draft angle for all sweep.
• And join all the sweep parts to make a Class C surface.
• Then Publicize it.

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5. FINAL TRIMS:

• <!-- [if !supportLists]-->Join class C surface with class A surface.
• <!-- [if !supportLists]-->Trim the class B surface with the join of class A and C surface.
• <!-- [if !supportLists]-->A close surface body will be created.

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<!-- [if !supportLists]-->·       <!--[endif]-->Now go to the part workbench, use close body surface command and convert closed surface into solid part.

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Creation of Engineering features

DOG HOUSE

• Dog houses are designed to avoid SINK MARK created on the CLASS-A surface by screw bosses and to solve the length issues when giving screw bosses which need to be assembled to other components.
• It is also useful when perpendicular screw bosses are required on the part to the tooling direction.

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• C thickness should be 40% of the main wall thickness T
• Height of B should be 3-6 mm

Procedure for creating the DOG HOUSE

• Create a side core axis.
• Chose the normal to-the-point method for creating the side core tooling axis.
• Create the dog house by creating a positioned sketch on the z-x plane. Using extrude or sweep method create dog hose outer walls.

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• Now close the top wall using offset surface and trim it
• 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.
• create dog house by offsetting side walls at a distance of 40% of wall thickness,
• Trim the dog house with the main door trim panel.

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• Create side core tooling axis in X direction
• Give drafts to the inside portions of dog house of 0.5 deg.

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 2. DRAFT ANALYSIS OF FINAL SOLID PART

• Before going to drat analysis go to customized view parameter >under mesh > check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compass to define the draft direction.
• In the colour scale change the draft angle to 3 degrees.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.
• If the whole surface is green then angle given to tooling axis is correct and the part will be manufacturable along that direction.

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ISOMETRIC VIEW

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LEFT SIDE VIEW

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RIGHT SIDE VIEW

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TREE STRUCTURE

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Conclusion:

     Hence CAD for the Dog House for the Door Trim considering the design rules for Dog house creation is done and Draft analysis is also performed for the final component successfully.