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

Challenge 3 - Door Trim Lower with Engineering Features

Aim:

Create the Door Trim Lower Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Create the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.

Objectives:

• A detailed report should be done explaining the draft analysis and the tooling axis creation.
• An explanation should be given on the way of creating the tooling axis, particularly the Bisecting method.

REPORT:

Heat Stakes:

Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications.

TOOLING AXIS:

The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction. Again, depending upon where you're working at, you may have a different name for it. So, when you go in and you create that Tooling Direction, you want to make sure that whatever you create is going to be used as a reference to design your data up against. So, when you add in your ribs, maybe some pockets, walls, whatever that may be, bosses, the walls are going to be drafted based off of the Tooling Direction. It's to make sure that the Core can pull apart from the Cavity, nice and clean.

Creation of tooling axis.

• Tooling axis here created is by selecting one of the natural axes as it clears the draft.
• Here, tooling axis is created by extracting one of the surfaces for creating a point and a new axis is created at that point.
• So, a flat face is extracted and created a point at its centre. Axis is also created at that point.
• Now, line is created using line tool and giving line type as point-direction and selected the point and direction for creating tooling axis and tooling axis is created along z direction.

Draft Analysis of Class A surface

Draft analysis is performed over Class A surface and every surface is obtained as clearing.

Creation Of Class B Surface

• Now, Class B surface has to be created. For this, multiple extract is used to extract surface in a single operation. Surfaces obtained are the offsetted for 2.5mm.
• The Unfilled areas have to be filled with multisection surface and join them together.
• Check the B surface by boundary command to make sure there is no gap in the surface.

Creation Of Class C Surface

• Now class C surface has to be created and it is created from the boundaries obtained from the Class A surface. This boundary is provided as the input curve for sweep command. Using sweep command, class C surface is created.
• Appropriate sweep is the provided considering the flash and considering manufacturing procedures. Surfaces are extrapolated if necessary.

• Closed surface command is performed with the help of part workbench and later the draft analysis is performed.

Heat Stake Creation

To create the heat stakes, I draw a sketch on the surface. After the creation of the sketch, I pad it to 15mm height and I gave a draft angle of 0.1 deg on both sides (inside and outside). Then using translation from point to point copies the heat stakes. Finally with union trim command added with the base body.

Locators Creation

Sketch the 4 way locator on the desired surface and position. Pad it with thickness of 1.3 mm and height should be more than the heat stakes. Give draft accordingly. Finally union trim it with the base surface.

Closed Body

Draft Analysis Of the Closed Body

Final Part