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.

OBJECTIVE

• Create a Tooling axis for the given CLASS -A surface.
• Create the CLASS B and C surfaces of door trim using the given CLASS-A surface.
• Create a final surface model and convert it into a solid body using the close surface command in the part design workbench.
• Create side core axis for the dog house
• Create Dog house on the B surface by considering the design rules.
• Perform draft analysis for both Class-A surface and Final part body.

Design Methodology:

Class-A surface means visible surface. It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.

Given CLASS-A surface

Procedure for Tooling axis creation:

• Check the best possible tooling direction by manually adjusting the compass.
• By analysing it is found that y axis as tooling direction would clear most of the faces without any difficulties.
• Now extract any surface and create a mid-point on it.
• Then create a dummy axis creating a line on the point and direction along the y-axis.
• Perform draft analysis to find whether the given axis clears the draft analysis. If not create a new tooling axis.

Draft analysis of CLASS-A surface:

CLASS-B surface creation :

Class-B surface means the thickness of a part it is not visible and is inside part. In other words, the Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Create offset surface of CLASS-A about 2.5mm inward direction.
• Check for discontinuity and rework on the offset surface using extract, multi-extract, multi sections surfaces.
• Join the surfaces and ensure the final CLASS-B surface created has no gaps.

CLASS-C surface creation:

The surface that joins class-A and class-B surfare that is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled.

• Create the sweep concerningerence to the surface and tooling axismulti-extractingting the CLASS-A boundary.
• Join the sweep surfaces by using commands like extrapolate, multi-sectiontion surface.
• Finally join all the sweep surfaces and ensure the continuity of the CLASS-C surface

Creating the Final surface:

For creating the Finals door trim surface, join the CLASS-A and CLASS-C surfaces together.

Then Extrapolate the B surfacea little bit outward direction to make sure that there would not be any gap when trimming with the joined surface.

Then trim the extrapolated CLASS-B surface with the Join surface (CLASS-A and CLASS-C)

Make a solid part body using the close surface command in the part design workbench.

Creation of Heat Stakes:

Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out.

Creation of 4 Way Locators:

4-way Locator mean you prevent movement at 2 axes (+X, -X, +Y and -Y) on the plane. Generally, you have cylindrical pin on the fixture and circular hole at workpiece part.

Creation of Ribs:

Ribs are used to strengthen the walls of your mould without increasing wall thickness which means that you minimise the problems that come into play when the wall thicknesses have to be increased. In essence, if the wall is too thick, warping and sinking can result so that the entire design may need to be rejected.

3D Part model in various orientations (Isometric, Front, Side, and Top View)

Draft analysis of final:-

Conclusion:-

Created 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.

Created the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.