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

AIM

Create the Dog House for the Door Trim considering the design rules

INTRODUCTION

DOG HOUSE

Dog house is an engineering feature used in plastic design. Dog houses are used as a support feature. Sometimes other engineering features 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 mold cavity. Dog house and other engineering components are built on the B-surface. 

OBJECTIVE

• Create a Tooling axis for the given CLASS -A surface.
• Create the CLASS B and C surfaces of door trim using the given CLASS-A surface.
• Create a final surface model and convert it into a solid body using the close surface command in the part design workbench.
• Create a side core axis for the dog house
• Create a Dog house on the B surface by considering the design rules.
• Perform draft analysis for both Class-A surface and Final part body.

Design Methodology

Class-A surface means visible surface. It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.

Given CLASS-A surface

Check for continuity of the given surface using Join or Boundary commands.

If there are no gaps on the A surface, create a tooling axis.

Procedure for Tooling Axis Creation

• Check the best possible tooling direction by manually adjusting the compass.
• By analyzing it is found that the y-axis as tooling direction would clear most of the faces without any difficulties.
• Now extract any surface and create a mid-point on it.
• Then create a dummy axis creating a line on the point and direction along the y-axis.
• Perform draft analysis to find whether the given axis clears the draft analysis. If not create a new tooling axis.

Draft analysis of CLASS-A surface

  

CLASS-B surface creation

Class-B surface means the thickness of a part that 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 surface. This is the surface that contains the engineering aspects of a model.

• Crean ate offset surface of CLASS-A about 2.5mm inward direction.
• Check for discontinuity and rework on the offset surface using extract, multi-extract, Fill, and multi-section surfaces.
• Join the surfaces and ensure the final CLASS-B surface created has no gaps.

• CLASS-C surface creation

  The surface that joins class-A and class-B surfaces is the class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled

  • Create the sweep concern inference to the surface and tooling axis multi-extracting-ting the CLASS-A boundary
  • Join the sweep surfaces by using commands like extrapolating, and multi-sectioning surface.
  • Finally, join all the sweep surfaces and ensure the continuity of the CLASS-C surface

Creating the Final surface

• For creating the final door trim surface, join the CLASS-A and CLASS-C surfaces together.
• Then Extrapolate the B surface a  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 with the Join surface (CLASS-A and CLASS-C)

Make a solid part body using the close surface command in the part design workbench

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 giving screw bosses which need to be assembled to other components.
• It is also useful when perpendicular screw bosses are required on the part of the tooling direction.
• C thickness should be 40% of the main wall thickness T
• The minimum width of the dog house is 12 mm.
• The height of B should be 3-6 mm
• The minimum draft for the do house degrees is 5 degrees to die to draw.

 

Procedure for creating the DOG HOUSE

• The First step 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 z-x plane. Using extrude or sweep method create dog hose outer walls.
• Now close the top wall using the multi-section surface command.
• Using the 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 dog house body part with the door trim component.

3D Part model in various orientations (Isometric, Front, Left Side, Right Side, and Top View)

DRAFT ANALYSIS

The Draft Analysis is a command that enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

• The procedure for performing the draft analysis is as follows
• Change the view mode of the component to be in customized parameter mode and then select the shading mode as materials.
• 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.

Draft analysis of DOG HOUSE using the Side Core Axis

Draft analysis of final Door trim component