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
a separate part. Also performing draft analysis and tooling axis separately. finally, all the surfaces have assembled into 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 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
CREATION OF TOOLING AXIS – BOTTLE HOLDER PROCEDURE
Check all the boundary whether it has connected or not
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
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 boundaries whether it has connected or not.
Check the model visually & choose the best tooling direction which should be easy to the 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
Add a bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING X DRIECTIO
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 SIDE TOOLING AXIS Y
Create a point on the surface and create a line using point direction, use direction as the y-axis.
Drag a compass and place it on-an 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 with a compass
CREATION OF SIDE TOOLING AXIS X
Create a point on the surface and create a line using point direction, use direction as the 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 with a compass
CREATION OF TOOLING AXIS – UPPER SUBSTRATE 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
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 the 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 the class a surface that is going to perform multisection surface
Join the surfaces by using 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 are 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 the positioned sketch and draw a locator sketch
Use pad commands for the sketch to till we are 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 of more than a heat stake
FLANGE
Create a flange for attachment of heat stakes 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
CALCULATION
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 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
MODELS IN VARIOUS ORIENTATIONS LOWER SUBSTRATE SOLID
BOTTLE HOLDER
ARMREST
UPPER SUBSTRATE
DOOR INTERIOR
TREE STRUCTURE
TREE STRUCTURE
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