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 Positioned sketch
All the should be sketches should be Iso-Constrained Ensured Proper Tree Structure
Geometrical sets should having 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 surface have assembled together in one catproduct
CREATION OF TOOLING AXIS – LOWER SUBSTRATE DRAFT ANLAYSIS
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 minimum draft angle is 3 degree
PROCEDURE
Check all the boundary whether it has connected or not.
Check the model visually & choose the best tooling direction which should be easy for draft.
After analyzing the above model the best tooling axis is y direction.
CREATING THE TOOLING AXIS
Create a point on centre of gravity of part by using measure inertia command and insert a axis system on the point as shown below
create a point -direction line parallel to the y axis and named as TOOLING AXIS as shown below
CREATION OF TOOLING AXIS – BOTTLE HOLDER PROCEDURE
Check all the boundary whether it has connected or not.
After analyzing the above model,we have to create tooling axis on YCheck the model visually & choose the best tooling direction which should be easy for draft.
CREATING THE TOOLING AXIS
Create a point 1 and insert a axis system on the point 1 as shown below
Create a intersection on XY plane for the given surface
Create a point to point line as shown below
Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING X DRIECTION
Create a intersection on ZY plane for the given surface
Create a point to point line as shown below
Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING Y DRIECTION
Add bisecting line by the reference of tooling facing x direction and tooling facing y direction and named as tooling axis
CREATION OF TOOLING AXIS – 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 for draft.
After analyzing the above model, there is an chance for undercut when we consider tooling axis from z.so we have to create tooling axis on x,y and also z
CREATING THE TOOLING AXIS
Create a point and insert a axis system on the point 1 as shown below
Create a intersection on ZX plane for the given surface
Create a point to point line as shown below
Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING X DRIECTION
Create a intersection on ZY plane for the given surface
Create a point to point line as shown below
Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING Y DRIECTION
Add bisecting line by the reference of tooling facing x direction and tooling facing y direction and named as tooling axis
CREATION OF SIDE TOOLING AXIS Y
Create a point on 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 correct view. lock the orientation of the compass.
Modify the above line by changing the direction along compass
CREATION OF SIDE TOOLING AXIS X
Create a point on 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 correct view. lock the orientation of the compass.
Modify the above line by changing the direction along compass
CREATION OF TOOLING AXIS – UPPER SUBSTRATE PROCEDURE
Check all the boundary whether it has connected or not.
Check the model visually & choose the best tooling direction which should be easy for draft.
After analyzing the above model the best tooling axis is y direction.
CREATING THE TOOLING AXIS
Create a point on centre of gravity of part by using measure inertia command and insert a axis system on the point as shown below
create a point -direction line parallel to the y axis and named as TOOLING AXIS as shown below
PERFORMING DRAFT ANALYSIS ON MODEL
To perform draft analysis open customize view parameters and choose the material
Insert a feature draft analysis by following these commands I insert>analysis>feature draft analysis
Align the compass on tooling axis that we created Open the color scale and enter the value is 3 deg.
If the whole body is green that all the faces is greater angle than the provided angle
DRAFT ANALYSIS REPORT OF CLASS A – UPPER SUBSTRATE
DRAFT ANALYSIS REPORT OF CLASS A – BOTTLE HOLDER
DRAFT ANALYSIS REPORT OF CLASS A – ARM REST
Along X DIRECTION
ALONG Y DIRECTION
ALONG Z DIRECTION
DRAFT ANALYSIS REPORT OF CLASS A – LOWER SUBSTRATE
CREATION OF CLASS B SURFACE
Insert a new gemeotrical set.Measure the value of thickness in master section.The value is 2.5mm Offset the class A surface to 2.5mm.
Check all the sub elements are formed if not try to fix it locally
LOWER SUBSTRATE CLASS B
BOTTLE HOLDER CLASS B
ARMREST CLASS B
UPPER SUBSTRATE CLASS B
CREATION OF CLASS C SURFACE
Analyse the class A once where the sweep is easier to create towards tooling direction Create a boundary using limitation points whereever possible for sweep
Sweep the above boundaries for industrial standard 3 degree towrads tooling axis
Now Create the c surface by using multisection solid where the sweep cant perform. Create a points on the curve as shown below and Create a line by using point to point line.
Split the both surfaces by using split command
Create a boundary by using on the class a surface that is going to pefrom multisection surface Join the surfaces by using multisection surface
By using the same method creating the c surface whereever the sweep is not possible After ,join all the c surface
Using the same method create c surfaces for all the parts
LOWER SUBSTRATE CLASS C SURFACE
BOTTLE HOLDER CLASS C SURFACE
ARMREST CLASS C SURFACE
LOWER SUBSTRATE CLASS C SURFACE CREATION OF B SIDE ATTACHMENT FEATURES DOG HOUSE
Extract the surface that we going to create a dog house
Insert a axis system. use positioned and draw a dog house sketch Sweep the sketch to 1.5 degree on the direction of main tooling axis
Add thickness to the above sketch of 2.5mm by using thicken surface
Dog house rule
B=4mm t=2.5mm C=0.4 * t=1mm
Extract the sweep and offset to b=4mm and c=1mm on all directions like the below
Trim the portion to get the required sketch Draft to 5 degree along second tooling axis Add fillet to all faces
Assemble the doghouse to lower substrate solid Translate the doghouse to wherever we need
To place pushpin on the doghouse create a ribs to doghouse Trim the ribs with doghouse
HEAT STAKES
Heatstakes is known as thermoplastic staking is the process of joining two dissimilar metals together Extract the surface that we going to create heat stake
Use positiioned sketch 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 0.3mm o all faces
Assemble the heat stake to lower subtrate solid
Maintain a 50mm minimum between two heat stakes Translate the heatstakes to wherever we need
Trim the all heat stakes with lowersubstrate solid
LOCATOR
Extract the surface that we going to create locator Use positiioned sketch and draw a locator sketch
Use pad commands for the sketch to till we required Draft the locator for minimum of 0.5 degree
Add fillet 0.5mm o all faces
Assemble the locator to lower subtrate solid
Maintain a 50mm minimum between two locator Translate the locator to wherever we need
Trim the all heat stakes with lowersubstrate solid
Maintian a height more than heat stake
FLANGE
Create a flange for attachment of heatstakes and locators at lower substrate
WEIGHT OF THE COMPONENT
Apply material plastic to the product
Use measure command to caluacute the weight of product
CALCUALTION
Lower substrate=0.5kg Bottle holder=0.266kg Arm rest =0.159kg
Upper substrate=0.181kg
The total weight of the product is =1.123kg DRAFT ANALYSIS REPORT OF UPPER SUBSTRATE
DRAFT ANALYSIS REPORT OF BOTTLE HOLDER
DRAFT ANALYSIS REPORT OF ARM REST
DRAFT ANALYSIS REPORT OF LOWER SUBSTRATE
CREATION OF PARTING LINE
Parting line is used to the differentiate between core and cavity NOTE = THE PARTING LINE BELOW IS CREATED WITHOUT ATTACHMENT
TREE STRUCTURE
MODELS IN VARIOUS ORIENTATIONS LOWER SUBSTRATE SOLID
BOTTLE HOLDER
ARM REST
UPPER SUBSTRATE
DOOR INTERIOR
CONCLUSION
Thus the door interior part has been created 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