Week 11 - Final project

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

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 cat part. Also performing draft analysis and tooling axis separately. finally all the surface have assembled together in one cat product

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 center 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 у TOOLING AXIS as shown below.

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 for draft.

• After analyzing the above model, we have to create tooling axis on Y

CREATING THE TOOLING AXIS

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

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

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

PERFORMING DRAFT ANALYSIS ON MODEL

To perform draft analysis open customize view parameters and choose the material

View Mode Customize it

DRAFT ANALYSIS REPORT OF CLASS A - BOTTLE HOLDER

DRAFT ANALYSIS REPORT OF CLASS A -ARM REST

DRAFT ANALYSIS REPORT OF CLASS A - Map Pocket

CREATION OF CLASS B SURFACE

1. Insert a new geometrical set

1. Measure the value of thickness in master section. The value is 2.5mm

1. Offset the class A surface to 2.5mm.

1. Check all the sub elements are formed if not try to fix it locally

LOWER SUBSTRATE CLASS B

Offset of Class A

CLASS B - UPPER SUBSTRATE

Offset of Class A

CLASS B - BOTTLE HOLDER

Offset of Class A

CLASS B -ARM REST

Offset of Class A

CREATION OF LOWER SUBSTRATE 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 standards 3 degree towards tooling axis

• Now Create the c surface by using multisection solid where the sweep cant perform.

• Create a points on the curve and Create a line by using point to point line. Split the both surfaces by using split command & then Perform the command

CREATION OF BOTTLE HOLDER CLASS C SURFACE

CREATION OF ARM REST CLASS C SURFACE

CREATION OF UPPER SUBSTRATE CLASS C SURFACE

CREATION OF 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

Heat stakes 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 positioned 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 0.5mm to 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 the all heat stakes with lower substrate solid

FLANGE

Create a flange for attachment of heat stakes and locators at lower substrate

CONCLUSION

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