Week 10 - Challenge 3 - Door Trim Lower with Engineering Features

Week 10 - Challenge 3 - Door Trim Lower with Engineering Features

DOOR APPLIQUE STEP FILE USED

THICKNESS 2.5mm,

Aim:

Create the Door Trim Lower Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Create the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.

Tooling Axis Creation:

Here i have used bisecting method to create Tooling axis,

• Firstly i had intersect line through had create dummy axis line via bisecting line create option.
• Second sketch create as per the another face intersection project through 3 Dgree line created
• Then finally bisecting line inputs of through above created 2 lines.
• Now finally created line as considered Tooling Axis of my component.

Given Class-A Surface :-

In automotive design, a class A surface is any of a set of free form surfaces of high efficiency and quality. 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.

Publications :

“Publishing geometrical elements is the process of making geometrical features available to different users”.

“A publication acts as a reference to a geometric or datum entity in a CATIA V5 part or product”.

slecting the geometrical elements for easier to show or hide when we work on the catia so that we have to select the Class A,B,C Surfaces & Tooling Axis, after that go to the tools & Select the publication Click yes & Click ok, then we got the publication on the tree As shown in figure below.

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 color ranges identifying zones on the analyzed 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 compasss to define the draft direction.
• In the colour scale change the draft angle to 3 degree.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.

Class B surface :

we offset the Class A surface and get the B surface body here we offset the 2.5mm value so we get the thickness is 2.5mm is mention in above so we offset the A surface for 2.5mm .

After the offset we get the surface but in that offset some patches of surface is missing so we required to solve it.

STEPS FOLLOWED

create B surface i just offet the Class A surface.

• Then I started to close ass the patches to one by one.
• Here I got 3 patches to close and i worked through using the extract, multi extract, extrapolate, untrim, Join, multi section surface & trim tools to resolve all the patches.
• Then I got trim together all to make final B surface and fillet provided as input gotton by Class A surface. Class C Surface:

  To create a Class C surface, first, extract the boundaries of the Class A Surface.

  Now using the Sweep option create the surface. To perform this operation, Go to the Toolbar > Sweep > Profile type > Line > Subtype: With draft direction > Guide curve 1- (select the extracted boundaries) the in Draft direction (select the tooling axis) angle and length as 3° and 4mm respectively and click ok.

  STEPS FOLLOWED

  To create C surface create boundry

• Then sweep done with tooling axis guide curve provision.
• all multiextract sweep as per tooling axis and reference to the surface.
• then join together to create C Surface. DRAFT ANALYSIS OF CLASS C SURFACE: C+A Surface creation: BEFORE PERFORMING FINAL TRIM OF CLASS A+C WITH CLASS B WE CHECK CONNECTIVTY AND CHECK BOUNDARY BY USING INTERSECT OF A+C WITH B TO FIND OUT ANY OPEN SURFACE OR GAPS. CLOSED SURFACE OR A+B+C SURFACE: DRAFT ANALYSIS VIEWS OF SOLID BODY:

  Locator & Heat Stake Design:

  LOCATORS

  Typically, locating pins are used for controlled, fine tolerance positioning of a work piece.

  A 2-way locating pin restricts motion along 1 axis (or 2 degrees of Freedom), like a round pin in a slot. Likewise, a 4-way pin restricts 4 degrees of freedom along 2 axes. A round locating pin located concentrically in a hole is a common application of a 4-way pin, and helps to further secure the piece.

  Here 4-way locator created with thickness 1mm ,draft 0.5 degree and the fillet value is 0.3 mm .

  4 Way Locator Design:

  Sketch done at projection points given along with class A.

  Then Pad then Draft for 0.5 Dgree and fillet provided upto 0.25 ~0.3mm.

  DRAFT ANALYSIS:

  

  2 Way Locator Design:

  Sketch done at projection points given along with class A.

  Then Pad then Draft for 0.5 Dgree and fillet provided upto 0.25 ~0.3mm.

  DRAFT ANALYSIS:

  

  HEAT STAKE

  Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications.

  Thermal staking should be considered when the parts to be assembled are still in the design stage. Several configurations for boss/cavity design are available, each with specific features and advantages. Their selection is determined by such factors as type of plastic, part geometry, assembly requirements, machining and molding capabilities, and cosmetic appearance. Heat staking can be performed using wide range of thermoplastic materials including polypropylene, ABS, polycarbonate and many others.

  The integrity of a thermal staked assembly depends greatly upon the geometric relationship between the boss and the thermal tip. Proper design will produce optimum strength with minimum flash.

  Heat Stakes design:

  Stake sketch created by the dimension taken from the videos.

  and every heat stakes have provided draft angle 0.5Dgree and fillets as same as locator fillets, fillet radius is 0.3mm and wall thickness is 2.5mm.

  heat stakes designed by following the design rules.

  DRAFT ANALYSIS:

  Boolean Operations for Assemble:

  All solid part assemble by boolean operations assemble, untrim the add as required operations.

  Now final part body created with locators and heat stakes.

  Draft Analysis for Final Part body & Locator & Heat stakes: Views: Final Preview Part Body: TREE STRUCTURE: