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

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 requirement of the draft angel and at the end perform the Draft analysis on the model and also create Heat Stakes and the locators.

OBJECTIVE:

• Tooling axis
• Class-B and Class-C surface creation
• Draft analysis
• Heat Stakes and the locators

Tooling axis:

To create the tooling axis, I extracted an edge from class A and created a point in the meddle of surface by using the point command and created a line at point through the Y-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 draft analysis check the surface highlighted with green colour on side of the surface the tooling axis is in the correct position and direction.

Draft analysis for class-A surface:

• Compass is place in Tooling axis.
• Then selected one side.
• Draft angle is > 3 Degree.
• Analysis the colour.

Class-A Surface:

Class-B surface:

• Initially, we need to offset the given Door trim class-A surface in the inner Y-axis direction to the required thickness (2.5MM).
• After that, we need to close the patches on the offset surface of the door trim, the patches are from 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.
• Extrapolating method uses for patches solving.

Class-C surface:

• Class-A surface use Class-C surface creation.
• Sweep the boundary of the class-A surface to trim with the class-B surface to make a closed body by using closed body, command in the part workbench we can get solid body from the closed surface of the Door trim.

Heat Stakes and Locators:

Heat staking:

Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set other. Heat Staking makes it easy to Boud metal to plastic and is commonly used in high volume / low-cost application such as automotive, IT and consumer appliances.

Shaping Plastic Using Heat and Pressure:

The plastic is deformed by heating it to a temperature above the glass transition temperature. Super-heated air or a thermodin is used for this, Pressure is then applied to create the stake. after the stake has been formed, the plastic should be cooled down again below the glass transition temperature. Colling is performed under constant pressure to ensure good fixation of the parts. Compressed air can be applied for cooling when a thermos especially for glass-filled plastics which often have a process window of less than 10 degree Celsius. When the temperature is too high, the glass fibres come out of the plastic which leads to a rough surface and adhesin to the thermos If the temperature is too low, the plastic will crack due to cold deformation.

Heat Staking Benefits:

• Similar and dissimilar materials may be joined: metal to metal, plastic to plastic, metal to plastic.
• Accurate control operating within a small process window
• Local heating resulting in no damage to surrounding materials.
• Processing of filled materials.
• No mechanical vibration.
• Many heat-stake shapes possible through custom designed tools.

I created the heat stakes and Locators by considering all the design parameters.

• Heat stakes buss create for 7 mm dimeter and hight is 20 mm.
• Edge fillet is 1 mm, 3 mm and 0.25 mm.
• Draft angle is 0.5 Degree.
• 2-way and 4-way Locators created.

Heat Stakes:

2-Way and 4-Way Locator's:

Draft analysis on Final component:

• Compass is place in Tooling axis.
• Then selected to the Class-B surface.
• Draft angle is 0.5 Degree.
• Analysis the colour.

3D View: