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

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

Aim
      The main objective of this challenge is to create the Door Trim Lower Plastic component through the given Class-A surface and to begin with, the tooling axis for the given Class-A Surface be created meeting the requirements of the draft angle and at the end, performed the Draft analysis on the model. Along with that to create the Heat Stakes and the locators considering the design rules for the door applique.

Contents

• Class A surface (given) 

• Tooling axis

               To create the 'Tooling Axis', the given class A should be observed thoroughly, For the given door handle class A,  Y-axis is the best suitable tooling axis, It is decided based on the complete visiblity of the class A. Then using the intersections made by the appropriate planes and the class A, We get a crossection sketch. The dummy axis is drawn on the y axis. Then the lines which are more or less parallel to the y axis are taken into consideration and drawn. By bisecting the two lines ,  As an output The Tooling clearing axis was derived.

• Draft analysis of class A surface

To perform the draft analysis of class A surface, click on Insert  >Analysis  > Feature Draft Analysis

Once the draft analysis toolbar is opened, The compass was selected and placed on the tooling axis, Then go to the display block and select the 'Analysis under the running point' command to check the angle for different sides on the class A surface. The color scale on the bottom visualizes, whether the draft angle meets the requirements or not (3 deg) by indicating the colors Green, Blue and Red.  

Screenshots of the Draft analysis for the given Class-A surface with colour scale variant

• Class B surface

    To create the class B surface from the class A, The class A was offset to 2.5 mm as required. There are some of the patches as issues. mostly those patches are from the fillet areas. So i used the Boundary and Multi section comand to solve the patched fillets by considering the entire class B. After further operations, The class B was successfully created.

• Class C surface

     To create a class C surface, I used the sweep command to avoid the continuity issue by considering the outer boundary of the class A surface. In the sweep command Acoordingly given the angles (when C surface tends to create perpendicular to the tooling axis, it was given 90 degree with recpect to the surface:when C surface tends to create parallel to the tooling axis, it was given 3 degree with recpect to the tooling axis), in this condition the class B surface is inside the class A surface so select the inside down arrow to sweep. ths class C surface was successfully created.

• Surface output of Door trim lower

   Then the closed surface was created by using the 'Join' & 'Trim' operation consisting the Class A, C and Class B surfaces.

• Solid Door trim lower

     To create the solid Door trim, Jump to part design workbench and select the closesurface option in the Surface based feature.

HEAT STAKES CREATION

                Using pad tool in part workbench the below heat stake was formed 

DOG HOUSE CREATION

•  Draft analysis of doghouse

2 WAY LOCATORS

4 WAY LOCATORS

FINAL SOLID DOOR TRIM LOWER

• The parent part body of Heat stake, Doghouse, 2 way locator, 4 way locator are copied, paste special (result with link), and translated to the appropriate places.
• Then performing Union trim Boolean operation, the final body was formed successfully.

 

Draft analysis of complete door trim lower

 

• Screenshot of the tree structure

 

• Screenshots of the solid model with the proper colour code of the draft angle in various orientations (Isometric, Front, Side, and Top View)