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

AIM:

To 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.

To create the Heat Stakes and the locators considering the design rules.

THEORY:

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.

Heat staking can be performed using wide range of thermoplastic materials including polypropylene, ABS, polycarbonate and many others. The integrity of a thermal staked assembly depends greatly upon the geometric relationship between the boss and the thermal tip.

PROCEDURE:

• Class A surface was provided to us along with many points in that surface for the creation of locators and heat stakes.

• To create a Tooling axis, extract a surface by observing the class A which will be suitable for tooling axis and then put a point in the middle and create a line and check with Draft Analysis if the line is suitable for Tooling axis.

• 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.

• Now, to create C class surface, Class A surface to be needed and by using Sweep, boundary, intersection and multi section surface, we created the C class surface. With that, Class A and C were added together.

• Trim the B surface with the above A+C surface to obtain a closed body using surfaces.

• Convert the surface body into a part body using the feature close surface option and perform a draft analysis to check whether the draft of 3mm is given.

• To create the heat stakes and locators, we created a concentric circle by sketch option and then pad it for 20mm. In another body, we created support ribs and the thicken it with neutral fibre for 1.3mm and given the draft of 0.5mm and then using Boolean operation we removed the unrequired body to make it a heat stake. After that, 3mm chamfer and edge fillet have been provided. Then, we copied the heat stake body and then paste special it at the top header geometrical set. And with Translation option and by point to point we copy-paste it in all the various given points. Finally, with boolean opreation's Union trim, we got the final desired output surface body.

Performed the draft analysis.

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