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

A) LOWER SUBSTRATE:

CREATION OF TOOLING AXIS:

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.

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.

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

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 where ever 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 can't be performed.
• Create a points on the curve as shown below and Create a line by using point to point line.
• After that, join all the c surfaces
• Using the same method create C surfaces for all the parts when the sweep feature is not performed properly.

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

• 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 & RIBS:

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 0.5mm 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

DRAFT ANALYSIS OF THE SOLID BODY:

B) MAP POCKET:

CREATION OF TOOLING AXIS:

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 analysing the above model, the best tooling axis is Y- direction.

CREATING THE TOOLING AXIS

• Create a point on the surface of the map pocket and insert an 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.

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 colour ranges identifying zones on the analysed element.

Most of the industries is using minimum draft angle is 3 degree.

 

CREATION OF CLASS B SURFACE

• Insert a new geometrical 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

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 where ever possible for sweep 
• Sweep the above boundaries for industrial standard 3 degree towards tooling axis

 

CREATION OF B SIDE ATTACHMENT FEATURES:

FLANGES:

DRAFT ANALYSIS OF THE SOLID BODY:

 

 C) ARMREST:

CREATION OF TOOLING AXIS:

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 analysing the above model, there is a 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 an 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

• Now bisect the two bisecting lines created as above.

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 colour ranges identifying zones on the analysed element.

Most of the industries is using minimum draft angle is 3 degree.

 

CREATION OF CLASS B SURFACE

• Insert a new geometrical 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

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 where ever possible for sweep 
• Sweep the above boundaries for industrial standard 3 degree towards tooling axis

CREATION OF B SIDE ATTACHMENT FEATURES:

FLANGES:

DRAFT ANALYSIS OF THE SOLID BODY:

D) BOTTLE HOLDER:

CREATION OF TOOLING AXIS:

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 analysing the above model, the best tooling axis is Y- direction.

CREATING THE TOOLING AXIS

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

• Now bisect the two bisecting lines created as above.

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 colour ranges identifying zones on the analysed element.

Most of the industries is using minimum draft angle is 3 degree.

CREATION OF CLASS B SURFACE

• Insert a new geometrical 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

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 where ever possible for sweep 
• Sweep the above boundaries for industrial standard 3 degree towards tooling axis

 

CREATION OF B SIDE ATTACHMENT FEATURES:

FLANGES:

DRAFT ANALYSIS OF THE SOLID BODY:

 E) PUSH PIN:

MODELS IN VARIOUS ORIENTATIONS

LOWER SUBSTRATE WITH B-SIDE FEATURES

MAP POCKET WITH B-SIDE FEATURES

ARM REST WITH B-SIDE FEATURES

BOTTLE HOLDER WITH B-SIDE FEATURES

DOOR INTERIOR WITH B-SIDE FEATURES

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