Week 11 - Final project
AIM : To create DOOR TRIM PANEL using the class A surface for the same, create B side features, do draft analysis and assemble the pushpin to the dog house.
The door trim panel consists of
- Door arm rest
- Map pocket
- Lower substrate
- Bottle holder
- B side features ( Locators, Heat stakes, Ribs, Dog house )
TOOLING AXIS
In order to perform analysis, we need to create tooling axis and in order to do that we need to check class A surface first. We need to check whether all the surfaces are closed or not using boundary option. Once inspection is complete, we need to create separate geometrical set for tooling axis. We need to choose the axis in such a way that all the pockets, holes, sections etc. should get covered. For example, once inspection is completed, we concluded that X,Y & Z axis is the tooling axis. Now we take reference point to create tooling axis.
CONSTRUCTION OF MAP POCKET
We first extract the class A surface and check whether the surface has any open boundaries or not. Then tooling axis is created. Then the class A surface is offseted to 2.5mm. to create the class B surface. The B surface is checked for any open boundaries, if found then we work on it to form one full surface.
Now we create class C surface using sweep option with draft angle of 3 degree.
Now trim both class A & C surface and check for any open boundaries.
Now trim all the class A,B & C surfaces to form one close body.
Now use close body option in part workbench & convert the surface body into solid body.
CONSTRUCTION OF BOTTLE HOLDER
We first extract the class A surface and check whether the surface has any open boundaries or not. Then tooling axis is created. Then the class A surface is offseted to 2.5mm. to create the class B surface. The B surface is checked for any open boundaries, if found then we work on it to form one full surface.
Now we create class C surface using sweep option with draft angle of 3 degree.
Now trim both class A & C surface and check for any open boundaries.
Now trim all the class A,B & C surfaces to form one close body.
Now use close body option in part workbench & convert the surface body into solid body.
CONSTRUCTION OF DOOR ARM REST
We first extract the class A surface and check whether the surface has any open boundaries or not. Then tooling axis is created. Then the class A surface is offseted to 2.5mm. to create the class B surface. The B surface is checked for any open boundaries, if found then we work on it to form one full surface.
Now we create class C surface using sweep option with draft angle of 3 degree and trim both class A & C surface and check for any open boundaries.
Now trim all the class A,B & C surfaces to form one close body.
Now use close body option in part workbench & convert the surface body into solid body.
CONSTRUCTION OF LOWER SUBSTRATE
We first extract the class A surface and check whether the surface has any open boundaries or not. Then tooling axis is created. Then the class A surface is offseted to 2.5mm. to create the class B surface. The B surface is checked for any open boundaries, if found then we work on it to form one full surface.
Now we create class C surface using sweep option with draft angle of 3 degree and trim both class A & C surface and check for any open boundaries.
Now trim all the class A,B & C surfaces to form one close body.
Now use close body option in part workbench & convert the surface body into solid body.
CREATING B SIDE FEATURES FOR ALL THE PARTS
Heat stakes are made with 5mm as inner dia and 7mm as outer dia. The heat stakes are provided with ribs in order to provide strength to it and act as supporting member to the flanges. Both the heat stakes & ribs are drafted to 0.5 degree.
Then we created 4-way and 2-way locators to arrest the 12 degrees of freedom. The height of locators should be greater than the heat stakes. Required fillets and draft angle of 0.5 degree is given to the locators.
Flanges are created to fix the component along with the heat stake. Proper master section curve for flanges were not available, so we did it according to our convenience.
CREATION OF DOG HOUSE
The dog house is created with the help of the drawing provided.
Once all the B side features are created pushpin are assembled on the dog house.
DRAFT ANALYSIS
Draft analysis technique is used to analyze whether our part model created in CAD is manufacturable or not. The part should get easily removed from the mould or die. No part can be ejected from the tool if it is having straight 90 degree angle from its base surface. A small draft angle is provided to each and every area of the component and we are providing a direction in which components should eject in order to easily remove the component from the tool.
Draft Angle is the amount of taper given to the molded parts perpendicular to the parting line. As the plastic cools it shrinks and sticks to the mould surface and therefore need draft angle while ejecting, and to avoid damage. Normal draft angle is 3 degree. Increasing draft value will increase manufacturing cost.
Now we need to check whether material mode of class A surface is in customize view parameters. Now go to Insert – Analysis - Feature draft analysis. Select the compass mode and drag the compass to the tooling axis of class A surface . Now select the surface to activate the surface and lock it using lock button. You can also do analysis during running point and move mouse all over the surface to check degree and draft angle.You can do analysis on full scale mode or quick scale mode. The color change shows change in draft angle.
