Challenge

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

DOOR TRIM LOWER WITH ENGINEERING FEATURES

TOOLING AXIS CREATION

for creating a tooling axis first we want to check the class a surface for a perfect tooling direction
then create a point on the surface
then create a line with point - direction method and project a line using axis direction perpendicular to the surface
then check for draft analysis that the tooling axis clears the Class A surface
in that test the tooling axis clears the class a surface and the tooling axis is usable and confirmed
make that your main tooling axis and publish the Class A and Tooling axis

CLASS B SURFACE CREATION

after finalising the tooling axis add a geometrical set for Class B creation
then offset the class A surface to 2.5mm inside
Find out the patches that are missing from the class b surface offset
and categorise them to 2 different geometrical sets
for patch 1 remove the series of fillets that are missing from patch 1 using join command
then extract the one unattached surface from the join and extract other
extrapolate each of them using boundary command and when extrapolation extract a little more for the class c trim
then trim those 2 extract and fix the patch 1
same with the patch 2
then find out the fillet values and add fillets to the B surface considering the offset value also
that final filleted surface will be our class B surface
extrapolate its boundaries a little more for class C trim

CLASS C SURFACE CREATION

select the boundaries of the class A surface and sweep that boundaries according to the ends of the surface ie, if the end of the surface is parellel to the tooling axis the sweep will be of 90 degree and sweep will be according to the reference surface
if the end of the surface is perpendicular to the tooling axis the sweep will be according to the draft direction that is the guide curve will be boundary and draft direction will be tooling axis and the draft angle will be 3 degree outside direction
when using sweep sweep to both top and bottom or front and back so that we can easily cut that with Class A surface

FINAL TRIM

initially trim the Class C surface with the Class A (for that initially extrapolate the class a with point continuity which includes the hole and the outer boundaries
extrapolate that to about a min of 3- 4 mm
then trim that with the class C surface

CLOSE SURFACE

close the final trimmed surface with using part workbench and close surface operator
close surface inside the partbody

4 WAY LOCATORS

add a new geometrical set for locators
check for the locations for the locators from the question
then mark points on the surface where we want locators
make a plane on one point and add a positioned sketch wrt to the plane so created and projection point as the point so created
then draw to like similar to that of the rib for the screw boss
then pad it on a new body naming 4 Way locator 1 using thick option and neutral fibre with a value of 1.3mm
then add chamfer on the 4 side edges with 3mm distance and 45 degree angle
then add fillets to that edges
then add respective draft of every face with draft angle 0.5 deg with its base as neutral plane and tooling axis as pulling direction
then add fillets on every faces
then copy the whole body and paste it on the project as paste special with attachment as a link then translate that to the other point that we had created before and rename it to 4 way locator 2
then assemble that 2 bodies into a new body named 4 way locators
then trim that with the main part body and remove the extrusion on the class A surface

HEAT STAKES

from the input point select a point and make a plane on a point
then add a positioned sketch with the plane and projection point as the input point
the draw 2 circle of dia 7 and 5mm
then pad it on a new body with height less than that of the locators
draft the body inside and outside with base as neutral element and tooling axis as pulling direction with an angle of 0.5 deg
then add a new sketch on geometrical set of heat stake for rib and add required dimensions for the rib
pad it to height that is less than the heat stake about 3:1 on a new body
draft the all sides of the rib wrt to its base and tooling axis with an angle of 0.5 deg
then trim the rib with base and remove the inside portion
then name that body HS 1
then copy and paste special as like the 4 way locators for 16 times to fill all the points
then translate that to the specific point by input and assemble these on a new body named HEAT STAKE
then trim that with the main body and remove any extensions present in the class a surface

FINAL DRAFT ANALYSIS

DIFFERENT 3D VIEWS

ISOMETRIC

FRONT

BACK

LEFT SIDE

RIGHT SIDE

TOP SIDE

BOTTOM SIDE

Ship work like this
in your own course.