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

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' workbench in CATIA V5. Performing the 'Draft Analysis' on the solid part body of the Door trim.

TOOLING AXIS:-

I have created the Tooling Axis by selecting the Mass Inertia, I selected the A Surface Component, and I created a non-associative geometry where the Center of Gravity is there and a point was created. From that point, I created a line through the Y-direction. That line has been considered the Tooling Axis.

B Surface Creation:-

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 2.5mm, so I offset the class A to 2.5mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multi-section surfaces command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface.

C Surface Creation:-

I used to create the C Surface by using the Sweep command which was for 87deg. Also used Sweep in the center handle for 90 deg. Then the A and C Surface were joined and trimmed, resulting in A+C Surface. The B surface sides were extrapolated for 5mm and the base was extrapolated for 0.5mm. Extrapolating the B Surface will be trimmed for 2.5mm thickness and the boundary also gets hidden which was named Output Surface. Then the Closed Surface applied on the Outout Surface and the Heat Stakes are about to fix.

HeatStakes:-

To create the locators, I created a sketch on the body. After creating the sketch, I pad it 20mm in height and thicken it to 1.3mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave 3mm of chamfer with 45deg of inclination and after I gave a fillet of 0.3mm radius.

To create the heat stakes, I draw a sketch on the surface. After the creation of the sketch, I pad it to 15mm height and I gave a draft angle of 0.5deg on both sides (inside and outside) and then I gave a fillet with a 0.25mm radius. After creating the heat stake, I created the ribs for supporting purposes. To create the ribs, I draw a sketch and padded it to 6mm in height and 1mm in thickness. After padding the ribs, I drafted 0.5deg in the tooling asix direction and filleted it with a 0.25mm radius. Finally, I union trim the ribs with a heat stake to remove the ribs, which are present inside the heat stakes.

Now I translated the heat stakes by copy-pasting them in the part body according to the requirement.

Final part body with 4-way and 2-way locators including all the heat stakes with supporting ribs.

Draft Analysis for Part Body:-

Some faces are not cleared properly, this is due to the curvature and inclinations on the class A surface.
The below-given images visualize the surfaces which are not cleared properly with a 3deg draft angle.

Conclusion:-

Hence the Heatstake of the door was trimmed and it was designed with the given procedure and it was attached below.