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

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

 

OBJECTIVE :

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

 

DESIGN METHODOLOGY:

  1. TOOLING AXIS CREATION-

         The Tooling Direction is basically the direction that the mold pulls apart. 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 doesn't interfere with the tooling axis and all the elements can be created.
• Extract a surface that is moreover a flat type create a point at the middle and create a tooling axis towards the Y-direction.
• The tooling axis is created for the component.

  2. PUBLICATION

• Publication is done to the component to make it visible and navigate easily.
• To publish the component go to tools > publications and then select the tooling axis and the class A surface.
• A separate tree structure is formed under the main part.

3. 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 color ranges identifying zones on the analyzed 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 the 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 an indication of the passing draft angle.
• Use a running point to check the angle of the component.
• The draft analysis is complete.

  4. CREATING CLASS B SURFACE

• Offset the surfaces to 2.5 mm to create the thickness
• Check whether all the surfaces are properly offset.
• some corner that is not offset, will be created with a multi-section command, fill.
• Join all the surfaces together and a class B surface will be created.
• While trimming with the class c surface some of the parts do not coincide, will extrapolate by selecting the outer boundary.

•   5. CREATING CLASS C SURFACE

  • Extract the boundary from the class A surface using the boundary command.
  • Using the 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 degrees> preview.
  • After getting sweep trim the output with class B surface to get the final output
  • Now open the part design workbench and using a closed body surface create a solid of the component.

  • 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
    • FINAL DRAFT ANALYSIS
    • VARIOUS VIEWS :
    • Front view
    • Side view
    • Top view
    • ISO view

    • 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.