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

Aim:

To create the door trim lower features of a plastic component through the given class-A surface by creating heat stakes and the locators considering the standard design rules.

Procedure:

Creation of Tooling Axis:

1. The given class-A surface is examined at different axis for the creation of tooling axis in suitable direction.
2. From the given class-A surface, it is observed that the Y-direction is the suitable direction for creating the tooling axis.
3. A point is created on one of the curves of the class-a surface using point command.
4. The tooling axis is created using line command using point-direction type in the y-direction.

Feature Draft Analysis:

1. By clicking on Insert>Analysis>Feature Draft Analysis, draft analysis dialog box appears.
2. Compass is activated using compass button and made to coincided on the tooling axis and locked and draft analysis is carried on.

Creating Class-B Surface:

1. The given class-A surface is offsetted to the required thickness i.e., 2.5 mm using the offset command and thus class-B surface is obtained with patches and gaps.
2. The patches and gaps are closed using various commands such as extract,extrapolate,fill,join and trim commands.

The finished class-B Surface is given below,

Creation of Class-C Surface:

1. The Class-C surface is created by extracting the boundary of class-A surface using boundary command.
2. The extracted boundary is swept using sweep command for a draft of 93 degree and thus Class-C surface is obtained.

Creating Class-A+B+C surfacde:

1. The Class-A and Class-C surfaces are extrapolated using boundary definition and trimmed to obtain class-A+C surface.
2. Similarly the Class-B surface is extrapolated and trimmed with Class-A+C surface and forms Class-A+B+C surface as output.

Creating Cad Part Model:

1. The Part design workbench is opened by selecting Start>Mechanical Design>Part Design.
2. Using Close Surface feature, the final output surface is converted into cad model.

Creation Of Locators:

1. A sketch of 4 way locators is drawn as per the design standards and made to solid using pad command and with a draft degree of 0.5 degrees and fillet of 0.25 mm and entry level chamfer of 3mm.
2. After the completion of pad work ,the locators are translated using translate command to different required locations.
3. Then the locators are trimmed with the final cat part.

Creation of Heat Stakes:

1. Similar to the locators ,a sketch is drawn with two circles of diameter 7 and 5 respectively and then padded to the required height.
2. Ribs are created as a support to heat stakes at lower height and then trimmed.
3. Then the heat stakes are translated for the required numbers.
4. Then all the heat stakes are trimmed with final cad part.

Creation of Ribs :

1. As per the given requirements , ribs are sketched,padded and then trimmed with the final cad part.

Creation Of Dog House:

1. The sketch for dog house is drawn at the requied place using positioned sketch.
2. The sketch is filleted and converted using thick surface command into solid.
3. The bottom removal portion is obtained using extract,offset,extrapolate,split commands.
4. The top removal portion is sketched ,padded and removed from the dog house.
5. The final dog house structure is translated and rotated as per the requirements.
6. Then the dog house feature is trimmed with the final cad part.

Final Finished Surface: