Week 10 - 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.  

 

1. Tooling axis creation:

      The first step is to observe the given class-A surface deeply and we can say the larger flat area which is perpendicular to the Tooling axis. So, by considering this thing for this class-A surface tooling direction will be in the Y-direction. so, we create the point on the flat surface as shown in the figure.

Then create a line perpendicular to the flat surface through that point.

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 2. DRAFT ANALYSIS OF CLASS A SURFACE

                         The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

• Before going to drat analysis go to customized view parameter >under mesh > check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compass to define the draft direction.
• In the colour scale change the draft angle to 3 degrees.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.
• If the whole surface is green then angle given to tooling axis is correct and the part will be manufacturable along that direction.

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3. CREATING CLASS B SURFACE

Extract the surfaces from the class A using multiple extract and untrim them. Use Extrapolate to make sure that all the untrims are properly intersected to trim and offset the surfaces to 2.5 mm to create the thickness. Trim the extra surfaces using trim command. Insert them into new geometrical set and name it with respective part names. Apply fillets to the model after creating the entire surface. If the edges are outside the fillet value will be added to the thickness of the component and if the edges are inside, the fillet value will be subtracted from the thickness of the component, for instance the thickness of the component Is 2.5 mm the fillet value is 15mm so the outside portion value should be 17.5 mm and inner edges should be filleted 12.5 mm to get uniform thickness. Perform trims one at a time so that it will be clear to understand.

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4. Class C Surface:

• Unhide the A Surface to Take a boundary as a reference to make C surface.
• Go to sweep line-> with Reference Surface 03-degree draft angle for all sweep.
• And join all the sweep parts to make a Class C surface.
• Then Publicize it.

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5. FINAL TRIMS:

<!-- [if !supportLists]-->·       <!--[endif]-->Join class C surface with class A surface.

<!-- [if !supportLists]-->·       <!--[endif]-->Trim the class B surface with the join of class A and C surface.

<!-- [if !supportLists]-->·       <!--[endif]-->A close surface body will be created.

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<!-- [if !supportLists]-->·       <!--[endif]-->Now go to the part workbench, use close body surface command and convert closed surface into solid part.

 

 

CREATION OF LOCATORS:

To create the locators, I created a sketch on the body. After creating the sketch, I pad it 25mm in height and thicken it to 1.5mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave 2mm of chamfer with 45deg of inclination and after I gave a fillet of 0.5mm radius. 

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CREATION OF HEAT STAKES:

To create the Heat stakes, I created a sketch on the body. After creating the sketch, I pad it 20mm in height and thicken it to 1.5mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave a fillet of 0.5mm radius. 

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 2. DRAFT ANALYSIS OF FINAL SOLID PART

• Before going to drat analysis go to customized view parameter >under mesh > check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compass to define the draft direction.
• In the colour scale change the draft angle to 3 degrees.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.
• If the whole surface is green then angle given to tooling axis is correct and the part will be manufacturable along that direction.

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ISOMETRIC VIEW

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LEFT SIDE VIEW

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RIGHT SIDE VIEW

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Conclusion:

Hence creation of the Door Trim Lower Plastic component through the given Class-A surface, Heat Stakes and the locators meeting the requirements of the draft angle and other design rules is successfully done and also the Draft analysis on the model is carried out.