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

Design -

• Class A surface is given by styling team  and this part gives to design engineer to create part with engioneering features.
• Tooling Axis we need to take specifically and check draft anaylisis and take best tooling axis by adjusting compass.
• Class B surface we need create from Class A surface by offsetting class A surface below a certain thickness . Offset can be done as per requirment . Usually offset value is 2.5 mm inward direction.
• For class B surface creation we need to check discontiunity and work on the offset surface by operations like extract , multi section surface , extrapolate , trim and split etc.
• There should be no any gap in class B surface .
• Class C surface will be created in class A surface by sweep operation which join class A and class B surface.Sweep can done as per requirement like with referance to surface or with referance to tooling axis and sweep angle will be provided .
• For Creating final trim join class A and Class C surface together. and there should be no boundry in this join.Extrapolate class B surface and this class  B surface should intersect with join class A and C. For ensure we should take intersection betwen Join and class B and make sure there should be no any black mark . it means there is still gap or surfaces are not intersecting with each other.
• Now, trim this updated class B surface with  join ( class A and class C).
• verify if there is still any boundry and no boundry should be present . Make this part as solid by closing the surface.

Heat Stake and Locator Creation-

• Heat Stake known as thermoplastic is process which process of joining two disimilar material 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.
•  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.

Rib Creation-

•   Ribs are a feature in plastic injection molded parts.
•  They are commonly used to provide additional support and strength to a part. Thickness and location are essential to rib design.

Parameters-

C thickness should be 40% of the main wall thickness T.

Height should be 3-6 mm.

Maximum draft would be 5 degree.

• First we need to create axis and probebly chosen point direction.Create sketch on plane required  by using extrude or sweep operation to create outer wall. sketch should be positioned and iso constrained.
• After close the top surface using multisection solid method. Using thicken command generate solid part of the dog house .
• Give proper  draft angle and provide fillets as per design rules.
• By boolean operation , union trim the dog house body with part body ( Door trim component).

DRAFT ANAYLISIS-

• Draft anaylis is command which enable to detect if the part drafted is easily removed . This draft anaylis is perform based on colour range identifying zone.
• Draft analysis is done after determining the tooling axis whether the minimum draft is maintained or not.

Colour range-

Green colour- Positive Draft

Red Colour - Not drafted

Blue colour- Negative Draft.

CONCLUSION-

Successfully created class B and C surface by given class A surface of the heat stakes and locator created tooling axis.Performed Draft analysis the final part and heat stakes and locator.