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

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

Given Class A Surface:

• Before proceeed make sure there is no gaps in between the given Class A surface,visually we can check it or by clicking boundary command.
• Find the best possible  tooling axis of the component. The tooling axis is the line which the mould or cavity opens.
• Look for the best possible tooling axis according to the product shape
• Check all three axis, Along Y and Z, it  is not faesible.so X direction is the best possible direction for tooling axis. 

Creating a Tooling axis 

Fig 1

 Fig 2

Fig 3

Main tooling axis

Create a point in the middle of the base and make a line through Z axis,this is our Dummy tooling axis,then create a intersect line through the point we created in the middle of the point, then help of point and sides of intersecting line create a Bisecting line as in  fig 1.

Repeat the process in Y direction also,then create an intersecting line with both line,the new line in X direction  will be the Main Toolng axis.(Fig 3)

Draft analysis

Now perform the Draft analysis using the Featured Draft Analysis tool in the tools.
Then after opening the draft analysis tool box ,go for the compass and place the compass alinged to tooling axis, and click on the lock symbol to lock the position. after alinging  click on the surface which we want to do draft analysis,minimum draft angle given is 3 degree.it shows green colour once its finished.

Creating Class B Surface:

Before creating B surface,make an extract copy of given Class A surface,do an offset of Class A surface by using offset tool at a distance of 2.5mm ,after offseting some of the offseted surfaces may have missing surafces,that we need to work on it,using the join option for removing the discontinued surfaces and create new surfaces by using extrapolation tool,do the necessary trims.

Then trim the extra surfaces to get required surface.

Now apply fillet to required areas,consider to add thikness value to all fillets.

Class C Surface

class C surface is made by extruding edges of class A through class B surface by swept tool,then do the trimming operation to remove unwanted surface

Closed Surface:

once class C is created join all the surfaces,we get closed surface,use boundary tool to check the part has any open profiles.

then open part workbench,apply closed surface tool on the final surface we have created to get the solid body

Solid body from closed surface

CREATION OF 4 WAY LOCATORS

After creating the sketch, pad it to 20mm height and thicken it to 1.3mm and  drafted it to an angle of  0.5deg in the direction of the tooling axis.then gave 3mm length chamfer with 45deg of inclination,fillet the edge with 0.25 mm

CREATION OF HEAT STAKES:

After the creation of the sketch, pad it to 15mm height and give a draft angle of 0.5deg on both sides (inside and outside) and then give a fillet with a 0.25mm radius. After creating the heat stake, create the ribsto heat stake for strengthening purpose. To create the ribs,  draw a sketch and padded it to 6mm in height and 1mm in thickness. After padding the ribs,  draft to an angle of  0.5deg to the tooling axis direction and fillet to a 0.25mm radius. Then trim the unwanted areas by using union trim with main plastic body

Draft analysis of heat stake and 4 way locator

for heat stake and 4 way locator give draft angle of 0.5 degree

Isometric view

Front view

Side view

Top view