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

A REPORT ON (CHALLENGE)  DOOR TRIM LOWER WITH ENGINEERING FEATURES

 

 

AIM:

To Create the Door trim lower component through the given Class-A surface.

 

OBJECTIVE :

• <!-- [if !supportLists]-->·       <!--[endif]-->To make sure that the model meets the design rules for heat-stake and locator creation
• <!-- [if !supportLists]-->·       <!--[endif]-->To construct a tooling axis and perform draft analysis on class-A surface
• <!-- [if !supportLists]-->·       <!--[endif]-->To create class-B and class-C surface and make closed surface
• <!-- [if !supportLists]-->·       <!--[endif]-->To create the B side feature in the component considering the design rules
• <!-- [if !supportLists]-->·       <!--[endif]-->Perform draft analysis on the final component

 

DESIGN METHODOLOGY:

 TOOLING AXIS CREATION-

         The Tooling Direction is basically the direction that the mold pulls a part. 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 Dye line or the Tooling Direction.

Open the given CAT part file.

Check for gaps between surfaces for that click on join and then preview.

If there’s any gap between the surfaces join them with a maximum tolerance of 0.003 mm.

Extract the boundary and dissemble the boundary.

Find the correct tooling axis where the material don't interfere with the tooling axis and all the elements can be created.

Extract a surface which is more over a flat type and create a point at the middle and create tooling axis towards Y-direction.

The tooling axis is created for the component.

DRAFT ANALYSIS

           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 degree.

The component changes to green in indication of passing draft angle.

Use running point to check the angle on the component.

The draft analysis is complete.

CREATING CLASS B SURFACE

Offset the surfaces to 2.5 mm to create the thickness

Check whether all the surfaces are properly offsetted.

One corner does not offsetted, will be created with multi-section command.

Join all the surfaces together and class B surface will be created.

While trimming with the class c surface some of parts not getting coincide, will extrapolate 4mm with selecting the outer boundary.

CREATING CLASS C SURFACE

Extract the boundary from the class A surface using boundary command.

  Using disassemble tool to divide the boundary as the boundary contains domains.

Use sweep command > choose profile type line > subtype as with draft direction > choose guide curve and draft direction > draft angle as 3 degree > preview.

After getting sweep then trim the output with class B surface to get final output.

Now open part design workbench and using close body surface create a solid of the component.

B SIDE FEATURES CREATION

 

CREATION OF HEAT STAKES:

Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order to fix the other.

Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such as automotive, IT and consumer appliances.

 

CREATION OF LOCATORS-

DOG HOUSE

Dog house is an engineering feature used in plastic design. Dog houses are used as support feature. Sometimes other engineering features like snaps, locators, and screw bosses are mounted on them to increase their strength.

Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mould cavity. Dog house and other engineering components are built on the B-surface. 

 

FINAL DRAFT ANALYSIS

   

CONCLUSION:

The Tooling Axis and the Solid CAT part with B side feature is created from the given Class A Surface and Draft Analysis is Performed.

 

 

 

 

 

Please find attached files.