Week 10 - Challenge 3 - Door Trim Lower with Engineering Features
Steps to create the Model:
- Create a point at (0,0,0) & a dummy tooling axis as shown in Fig with a yellow line. Use draft analysis to check the coreectness of tooling axis, if the surface are above or equal to 3deg draft then proceed further.
- I have added a side core tooling axis to clear the pocket. If we will try to clear the pocket with the main tooling axis the edges of the pocket will not be as desired.
- Offset all planar surfaces opp. to Class-A. Extrapolate & Trim them one by one and combine them as one. Give the necessary fillet at all corners. You can get values of fillet by extracting fillets of Class-A, untrimming it & using measure to get value of fillet. Don't forget to add/subtract material thickness as required.
- Create boundary of Class-A. The C-Surfaces which is parallel to tooling axis use sweep as draft to create C-Surface , select the tooling axis as draft direction. For other faces use sweep perpendicular to the surface.
- Extrapolate & trim the C-Surfaces, trim Class-A with Class-C Surface. Finally extrapolate Class-B Surface & trim them to get close volume.
- Use the close surface command to get the solid body. Use draft analysis to check the final result
- Create a point and a plane at the surface of the body where the locator has to be made, then create a center-line sketch for the 4-way locator.
- Pad & thicken the sketch to give the necessary fillet, draft & chamfer. Copay the same part in all desired positions.
- Use the Union Trim command to assemble it to the part body.
- Similarly, create a sketch for Heat Stake. Use the Power Copy tool to copy Heat Stakes at the desired location and union-trim it.
Design Consideration:
The Locator should follow all the design rules ribs design like:
Draft-0.5deg per side
Thickness = 0.4*wall thickness
Height less than 5*(nominal wall thickness)
The Locator height should be greater than height of heat stakes.
Fillet - 0.25mm
I.D of Heat Stakes = 4.5-5mm
O.D of Heat Stakes = 7-7.5mm