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

DOOR TRIM LOWER WITH ENGINEERING FEATURES

OBJECTIVE: To create the Door Trim Lower Plastic Component from the given Class-A Surface and also creating the Heat Stakes and the Locators by considering the design rules for the Door Applique.

CREATING TOOLING AXIS

• Tooling axis is created using the bisecting method.
• Extracted the base flat surface of class A and created a reference point.
• Intersected the class A along the xy plane created and drawn 2 lines along the sloped faces.
• Then created a bisecting line for the 2 lines through the reference point and created the tooling axis.
• Published the tooling axis.

DRAFT ANALYSIS ON CLASS A SURFACE

• Changed the view mode to Material mode.
• Insert>Analysis>Feature draft analysis
• Activated the compass and then by dragging the red point, placed the compass along the tooling axis and locked it.
• Clicked on the part and analysed the draft angle of component.
• Considered the min. draft angle as 3 degree.
• The green colour area shows that the component satisfies the given draft angle.

CREATING CLASS B SURFACE

• To create class B surface, the whole class A surface is offseted by 2.5 mm.
• Some fillet patches were missing.
• So i removed all the fillets and extracted the Class B as 4 parts.
• Then i used the Multiple extract,Extrapolate and Trim commands to work on it and created a complete class B surface.
• All the fillets were given with proper values.

CREATION OF CLASS C SURFACE

• Using boundary command created separate boundaries on the edges of the class A surface and used the SWEEP command to create class C.
• 3 degree draft were given to the edges which were perpendicular to the tooling axis.
• And some edges were sweeped separately and used the multi section to complete the gaps or filleted edges.Then trimmed the intersecting parts.
• For the center sweeped c which was not touching any other sweep, used the Join command to join all the C surface together.
• Then joined the class A and class C surafces together.
• After that this class A+C join were trimmed with the class B surface to get a closed component.
• Used the boundary command to check whether the component has any open boundaries or not.
• Then in the part design workbench used the CLOSE SURFACE command to create a solid out of the component.

CREATING LOCATORS

• Created a reference point and a plane tangent to the surface.
• Then a positioned sketch was created on that plane.
• padded the sketch to create the Locator.
• Given 0.5 degree draft to the faces with pulling direction as the Tooling axis.
• Then chamfered the top corners.
• Using the boolean operation trimmed the locator with the Solid component body.
• Then 0.25mm fillets were provided to the edges of the Locators.

CREATING HEAT STAKES

• Basic sketches were made on the planes which were created on the reference points that were already provided with the class A surface.
• Each Heat stake was created separately using pad command.
• 0.5 degree draft were given to all the faces and chamfered the sharp edges of the ribs of heat stakes.
• Using the boolean operation trimmed the heat stake with the Solid component body.
• Then 0.25mm fillets were provided to all the edges.

DRAFT ANALYSIS ON FINAL SOLID COMPONENT

• Draft analysis was performed on the final component in the same method which i used for the draft analysis of class A surface.