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

AIM:-  Door Trim Lower with Engineering Features

OBJECTIVE:-

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.   

OVERVIEW:- initially, we need to offset the given Door Trim class A surface in the inner direction to the required 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 together to make a proper class B surface and now sweep the boundary of the class  A surface to trim with the class B surface to make a closed body.

By using the closed body command in the Prat 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 surfaces are drafted properly or not (The draft angle for the plastic component is 0.5deg to 3deg).

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 x-axis.

Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not.

If in the draft, analysis check the surface highlighted with green colour on both sides of the surface the tooling axis is in the correct position and direction. 

CLASS B SURFACE:

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

CLASS C SURFACE:

I used the sweep command to create the class C surface concerning the boundary of the class A surface.

Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface.

Once we sweep all the surface boundaries of class A, extrapolate the swept surfaces until both surfaces got intersect properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the centre hole of the door trim. Now, join both class A and sweep boundary to get the complete class C surface. 

Class C surface:

CREATION OF HEAT STAKES:

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:-