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

To create the Door Trim Lower Plastic component through the given Class-A surface.
To create the tooling axis for the given Class-A Surface considering the draft angle and perform the Draft analysis on the model.
To create the Heat Stakes and the locators considering the design rules.

Fig.1: Door Trim Lower.

Tooling Axis:-

The direction with respect to the component in which the mould opens and closes is the tooling axis. Basically, it defines the direction in which the mould pulls apart.

Procedure to create the tooling axis:-

For this model,

• First, the given Class-A surface was observed carefully from every direction and found that in Y-direction the Tooling Axis can be created.
  
  
  Fig.2: Given Class-A surface.
  
  
• Then, one bottom surface was extracted and a point was created in the middle of that surface.
  
  
  Fig.3: Point on the extracted surface.
  
  
• Then, a line was created passing through that point along Y-Axis.
• Then, draft analysis was done for the Class-A surface considering the line as tooling direction.
• When no error was found in the draft analysis the line was named as Tooling Axis.
• Hence, the Tooling Axis was created.
  
  
  Fig.4: Tooling Axis.

Draft Analysis:-

The draft analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft angle and the tooling direction provided. It also enables us to detect if the part will be easily removed from the mould or not. The ejection of the part from the mould depends on the draft angle.

Fig.5: Draft analysis of the given Class-A Surface.

Class-B Surface:-

Class-B Surface was created by offsetting the Class-A surface by 2.5 mm. Then the surface patches were solved.

Fig.6: Class-B Surface.

Class-C Surface:-

Class-C Surface was created using the boundary of the class-A surface and sweeping it along the tooling direction and perpendicular to the class-A surface as per requirement. Then the edges of the sweeps were extrapolated and trimmed with each other.

Fig.7: Class-C Surface.

Combining A, B and C Surface:-

All three surfaces were combined by joining the Class-A and Class-C surfaces and trimming them with the Class-B Surface. At last, it was converted into the Solid Model by using the Close Surface command.

Fig.8: Joined Class-A, Class-B, and Class-C Surface.

Fig.9: Solid Model.

Locator Design:-

Locators are the supporting member basically it helps in locating the correct position of the component during assembly.
After making solid model locators were created following the locator design rules. After creating a locator in one position it was copied and translated to another position also.

Fig.10: Sketch for the locator.

Fig.11: Locator.

Fig.12: Model with locators.

Heat Stake Design:-

Heat Stakes are provided to avoid the heat sink mark on the class A surface.
After Locator, Heat Stakes were created following the screw boss design rules. After creating a heat stake in one position it was copied and translated to all other positions.

Fig.13: Sketch for Heat Stake.

Fig.14: Sketch for Heat Stake Rib.

Fig.15: Heat Stake.

Fig.16: Model with Heat Stake.

Fig.17: Different views of the Door Trim Lower.

Fig.18.1: Tree Structure for the Geometrical Sets and the Part Body of the Model.

Fig.18.2: Tree Structure for the Geometrical Sets and the Part Body of the Model.

Fig.19: Draft analysis of the Door Trim Lower.

Fig.20: Draft analysis of the Locator and Heat Stake, considering the draft angle of 0.45 degrees.

Conclusion:-

The Door Trim Lower Plastic component was designed using the given Class-A surface. The tooling axis was created for the given Class-A Surface considering the draft angle and the Draft analysis was performed on the model. The Heat Stakes and the locators were also created considering the design rules.