Challenge

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

AAmit Kumar17 Oct 2023

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.

Creation of the Heat Stakes and the locators considering the design rules.

THEORY:

Draft: The draft is the amount of taper for moulded or cast parts perpendicular to the parting. line. Draft angles are a design consideration that makes it much easier for a part to release cleanly from mould. A draft angle is calculated as a degree measurement (or, less often, an inch or millimetre measurement) from the vertical axis of mould, and it helps account for thermoplastic shrinkage, a practical reality of the injection moulding process for most materials.

Draft angles are generally a requirement of injection moulding design (though there are a select few soft materials, like nylon, that can get away with draft angles of zero). The draft should be a part of the design for manufacture, and all stakeholders and contributors should be aware of its need at the outset of the design process. This includes product designers, design engineers etc and this allows considerations for design requirements to be taken into account. Any draft is always better than no draft.

Importance of Draft:

By accounting for thermoplastic shrinkage during the cooling process, draft angles significantly reduce friction between the finished, cooled part and the side of the mould, Not only does this create a much easier release process, but it also offers several other benefits, depending on the design of the part which is as follows:

• Reduces the chance of damage to the part due to friction during the release.

• Reduces wear and tear and chances of damage to the mould.

• Ensures a uniform, smooth, unscratched finish when required.

• Ensures the integrity and uniformity of other surface finishes and textures.

• Reduces overall cooling time by lessening or eliminating the need for unconventional ejection setups.

• Most, if not all, of these benefits, offer either direct or indirect overall production cost reductions.

Tree Structure

PROCEDURE:

1. Open the given class A surface. Ensure that all its boundaries are connected.

Tooling Axis:- I was taken a point on surface of class A and draw a line through the point in Y direction.

Draft Analysis

The analysis is done with 3 degree draft angle. As we can seen all the surfaces in green colour are 3 degree or more than 3 degree.

Creation of Class B Surface:

Create a B surface at an offset of 2.5mm with respect to the A surface given. We can notice that few of the elements will be missing after offset. Using features like the extract, extrapolate, multisection etc, fill up the missing elements.

The B surface will look as below after following the above procedure.

Creation of Class C Surface:

For creating Class C surface we have extracted the boundry from Class A.
Now this boundry is sweep along the draft direction with a 3deg draft.

Trimed or Join

Class B and Class C:

We make sure that there is not any open boundry between class A and class C, we have to join them to created the single body.

Final Trimed Body

Trim the B surface with the above surface to obtain a closed hollow body using surfaces.

Creation of Locater

Create a 4 way locator using a sketch on the body. After creating the sketch, pad it 20mm in height and thicken it to 1.3mm and draft it with 0.5deg in the direction of the tooling axis. Give 5mm of chamfer with 45deg of inclination and a fillet of 0.30mm radius.

Creation Of Heat Stack

Draw a sketch on the surface. After the creation of the sketch, Pad it to 15mm height and a draft angle of 0.5deg on both sides (inside and outside) and then provide a fillet with a 0.30mm radius. After creating the heat stake, create the ribs for supporting purposes. To create the ribs, draw a sketch and padded it to height less than that of the heat stake and 1mm in thickness. After padding the ribs, drafted 0.5deg in the tooling axis direction and fillet it with a 0.30mm radius. Finally, use union trim on the ribs with a heat stake to remove the ribs as per the requirement, which are present inside the heat stakes.