Week 11 - Final project

AIM

To create a door interior part from the inputs of class A surface along with the 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 the Positioned sketch
• All the should be sketches should be Iso-Constrained
• Ensured Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• Create thickened part using the master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Creating 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 assembled together into one CATproduct

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 the industries is using a minimum draft angle is 3 degree

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 center of gravity of part by using the measure inertia command and insert an axis system on the point as shown below

• create a point-direction line parallel to the y axis and named TOOLING AXIS as shown below

CREATION OF TOOLING AXIS – BOTTLE HOLDER

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.

• 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 assembled together into one catproduct

  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 the industries is using a minimum draft angle is 3 degree

  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 the measure inertia command and insert an axis system on the point as shown below

  
  create a point-direction line parallel to the y axis and named 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 a tooling axis on YCheck the model visually & choose the best tooling direction which should be easy to draft.

  CREATING THE TOOLING AXIS

  Create a point 1 and insert an axis system on the point 1 as shown below

  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 by 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 below

  
  Add a bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING Y DIRECTION

  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 to draft.

  After analyzing the above model, there is a chance for undercut when we consider the tooling axis from z.so we have to create a tooling axis on x,y, and also z

  CREATING THE TOOLING AXIS

  Create a point and insert an axis system on the point 1 as shown below

  Create an intersection on the ZX 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 above and named as TOOLING FACING X DIRECTION

  Create a 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 above and named as TOOLING FACING Y DIRECTION

  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 the surface and create a line using point direction, use direction as a 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 SIDE TOOLING AXIS X

  Create a point on the surface and create a line using point direction, use direction as a 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 – 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 to draft.

  After analyzing the above model the best tooling axis is the y-direction.

  CREATING THE TOOLING AXIS

  Create a point on center of gravity of part by using the measure inertia command and insert an axis system on the point as shown below

  create a point-direction line parallel to the y axis and named 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 the 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 are 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 geometrical set. 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 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

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

  Sweep the above boundaries for industrial standard 3 degrees towards the tooling axis

  Now Create the c surface by using a multisection solid where the sweep cant perform. Create a point on the curve as shown below and Create a line by using point to point line.

  Split both surfaces by using the split command

  Create a boundary by using on the class a surface that is going to perform a multisection surface Join the surfaces by using a multisection surface

  By using the same method creating the c surface wherever 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 an axis system. use positioned and draw a dog house sketch Sweep the sketch to 1.5 degrees in the direction of the main tooling axis

  Add thickness to the above sketch of 2.5mm by using thickened 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 in all directions like the below

  Trim the portion to get the required sketch Draft to 5 degrees along the second tooling axis Add fillet to all faces

  Assemble the doghouse to lower substrate solid Translate the doghouse to wherever we need

  To place a pushpin on the doghouse create ribs to the doghouse Trim the ribs with a 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 a heat stake

  Use positioned sketch and draw a heat stakes sketch

  Use pad commands for the sketch to till we required to Draft the stakes minimum of 0.5 degree

  Add fillet 0.3mm o all faces

  Assemble the heat stake 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 the locator Use positioned sketch and draw a locator sketch

  Use pad commands for the sketch to till we required to Draft the locator for a minimum of 0.5 degree

  Add fillet 0.5mm o all faces

  Assemble the locator to lower substrate solid

  Maintain a 50mm minimum between two locators Translate the locator to wherever we need

  Trim all heat stakes with lower substrate solid

  Maintain 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 the measure command to call acute the weight of the 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 ARMREST

  DRAFT ANALYSIS REPORT OF LOWER SUBSTRATE

  CREATION OF PARTING LINE

  A parting line is used to the difference between core and cavity NOTE = THE PARTING LINE BELOW IS CREATED WITHOUT ATTACHMENT

  TREE STRUCTURE

  MODELS IN VARIOUS ORIENTATIONS LOWER SUBSTRATE SOLID

  BOTTLE HOLDER

  ARMREST

  UPPER SUBSTRATE

  DOOR INTERIOR

  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 rules followed in tier 1 and OEM industries in CATIA v5