Week 11 - Final project

AIM:

To create a door interior part from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in CATIA v5

SOFTWARE USED:

CATIA V5

OBJECTIVES:

• Create a sketch by using a Positioned sketch
• All the should be sketching should be 'so-Constrained
• Ensured Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• Create thickened part using master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Creating of Draft analysis & Tooling analysis
• Creation of parting lines and check tooling feasibility

INPUT OF CLASS A SURFACE:

Since the input class, A surface is containing four different parts(class A). So class b and c for all the surface has been created in separate catpart. Also performing draft analysis and tooling axis separately. finally, all the surfaces have been assembled together in one cat product.

CREATION OF TOOLING AXIS — LOWER SUBSTRATE
DRAFT ANALYSIS

Draft analysis in CATIA is a command that is used to detect if the part you drafted will be easily removed from the mold. it is performed based on color ranges identifying zones on the analyzed element.

Most of the industries is using a minimum draft angle is 3 degrees.

PROCEDURE:

• Check all the boundaries whether it has connected or not.
• Check the model visually & choose the best tooling direction which should be easy to draft.

• After analyzing the above model the best tooling axis is the Y direction.

CREATING THE TOOLING AXIS:

• Create a point on the center of gravity of part by using a surface.

• Create a point- Direction line parallel to the Y direction as shown above.
• The line is named tooling Axis.

CREATION OF TOOLING AXIS — BOTTLE HOLDER

PROCEDURE:

• Check all the boundary whether it has connected or not
• Check the model visually & choose the best tooling direction which should be easy to draft.
• After analyzing the above model, we have to create a tooling axis on Y.

CREATING THE TOOLING AXIS:

• creating a point and inserting an axis system on point one as shown in the below image.
• create an intersection on the XY plane for the given surface.

• create a point to point line as shown below

• add a bisecting line as shown below be the reference of two lines created above and named as Tooling facing X direction.

• Create an intersection on the ZY plane for the given surface.

• Create a point to point line as shown

• add the bisecting line as shown below by the reference of two lines created above and named Tooling facing Y Direction.

• Add a bisecting line of tooling facing Y and X-direction tooling axis and named as Tooling axis.

CREATION OF TOOLING AXIS — DOOR ARMREST

PROCEDURE:

• Check all the boundary whether it has connected or not
• Check the model visually & choose the best tooling direction which should be easy to draft.

• After analyzing the above model, there is a chance for undercut when we consider tooling direction from Z. so we have to create a tooling axis in the Y direction also.

CREATING THE TOOLING AXIS:

• Create a point and insert an axis system on point one as shown below

• create an intersection on the ZY plane for the given surface

• create a point to point line as shown below

• add a bisecting line as shown below by the reference of two lines created below named as Tooling facing Z direction

• Creating an intersection on the ZX plane for the given surface.

• follow same as above axis creation

• Add a bisecting line as shown above and named as Tooling facing z-direction.
• Add bisecting by the reference of tooling Facing X direction and y direction and named as tooling axis.

CREATION OF SIDE TOOLING AXIS Y

• Create a point on the surface and create a line using point direction, use direction as y-axis. 
• Drag a compass and place it on-axis that we created. Adjust the compass till we get the correct view. lock the orientation of the compass.
• Modify the above line by changing the direction along a compass

CREATION OF TOOLING AXIS — SMAP POCKET

PROCEDURE:

• Check all the boundary whether it has connected or not
• Check the model visually & choose the best tooling direction which should be easy to draft.

• After analyzing the above model the best tooling axis is the Y direction.

CREATING THE TOOLING AXIS:

• Create a point on the surface and use line point and direction to create a Tooling axis Y direction.

 Drafting analysis on the Class A surface:

• After creating the solid body we will perform the draft analysis of the whole part body.
• First, change the parameter to material mode and then go to perform draft analysis Go to Insert > analysis > feature draft analysis.
• Click on the compass icon & align with the tooling axis.

DRAFTING ANALYSIS REPORT OF CLASS A SURFACE - LOWER SUBSTRATE

DRAFTING ANALYSIS REPORT OF CLASS A SURFACE - BOTTLE HOLDER

DRAFTING ANALYSIS REPORT OF CLASS A SURFACE - DOOR ARMREST

DRAFTING ANALYSIS REPORT OF CLASS A SURFACE - SMAP POCKET

CREATION OF CLASS B SURFACE:

• Insert a new geometrical set to measure the value of thickness in the master section. the value is 2.5mm.
• offset the class A surface to 2.5mm
• check all the elements are formed if not try to do patchwork.

CLASS B SURFACE - LOWER SUBSTRATE

CLASS B SURFACE - BOTTLE HOLDER 

CLASS B SURFACE - DOOR ARMREST

CLASS C SURFACE - SMAP POCKET

CREATION OF CLASS C SURFACE:

• Analysis the class A once where the sweep is easier to create towards tooling direction
• create a boundary using the limitation points wherever possible for a sweep.

• Sweep the above boundaries for industrial standard 3 degrees towards Tooling Axis.

• Now create the C surface by using multisection solid wherever the sweep cant perform.
• Create a boundary using a Class A surface that is going to perform a multisection surface.
• now trim the surface with class B to form a closed surface.

LOWER SUBSTRATE CLASS C SURFACE:

CLASS C SURFACE - BOTTLE HOLDER:

CLASS C SURFACE - DOOR ARMREST:

CLASS C SURFACE - SMAP POCKET:

CREATION OF B SIDE ATTACHMENT FEATURES:

DOG HOUSE

• Extract the surface that we going to create a dog house
• insert axis system use the positioned sketch and draw a dog house sketch.

• pad the sketch for the required length.

Use Drafting commend to create an angle degree of 3 along the tooling axis as a direction.

shell the dog house for the 2mm thick wall

• create a profile of inside the dog house 
• repeated the same as the pad 
• remove the pad by using boolean commend to form a profile.

Draw the inner wall ribs for the dog house.

The sketch should be iso constrained.

finally split the Dog house profile by using the extracted surface and archiving the given dimension for the standard.

Give the chamfer for 0.8*45degree as required.

• Assemble the Dog house to lower substate solid.
• Translate the dog house to wherever we need it.
• Assemble the pushpin on the doghouse with ribs using constraints.

HEAT STAKES:

Heat stakes are known as thermoplastic staking is the process of joining two dissimilar metals together.

• Extract the surface that we are going to create Heat stake.
• use positioned sketches and draw a heat stakes sketch.

• use pad commands for the sketch to till we required.
• draft the stakes minimum of 0.5 Degree.
• add fillet 0.25mm to all faces.
• Assemble the heat stakes to lower substrate solid.

• Maintain a 50mm minimum between two heat stakes
• Translate the heat stakes to wherever we need
• trim all heat stakes with lower substrate solid.

LOCATOR:

• Extract the surface that we going to create a locator
• use the positioned sketch and draw a locator sketch

• use pad commands for the sketch to till we required.
• draft the stakes minimum of 0.5 Degree.
• add fillet 0.25mm to all faces.
• Assemble the heat stakes to lower substrate solid.

• Maintain a 50mm minimum between two heat stakes
• Translate the Locators to wherever we need
• trim all Locators with lower substrate solid.

FLANGE:

create a flange for attachment of heat stakes and locators at the lower substrate.

WEIGHT OF THE COMPONENT:

• Apply material plastic to the product
• use measure inertia to calculate the weight of the product.

CALCULATION:

Lower substrate = 0.614kg

Bottle holder = 0.346kg

Door armrest = 0.193kg

smap pocket =0.215kg

pushpin =0.005kg

Total weight of the product is = 1.378lg

DRAFT ANALYSIS REPORT:

• LOWER SUBSTRATE:

• BOTTLE HOLDER:

• DOOR ARMREST:

• SMAP POCKET:

CREATION OF PARTING LINE:

A parting line is used to the difference between core and cavity.

TREE STRUCTURE:

Models in various orientations SOLID:

LOWER SUBSTRATE SOLID:

BOTTLE HOLDER:

DOOR ARMREST:

SMAP POCKET:

CONCLUSION:

Thus the door interior part has been created from the inputs of class A surface along with the master section by following the design rule followed in tire 1 and OEM industries in CATIA v5.