Week 11 - Final project

AIM :- Development of a Door Trim panel

Draft Analysis ?

The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line.

Draft angles ?

Draft angles are very important in thermoforming product design. If the product is formed onto a female or negative mold, it shrinks away from the mold sidewalls. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles. If the product is formed onto a male or positive mold, it shrinks onto the mold sidewalls. A draft angle of 1–5 degrees is recommended for all male or positive products.

here we are taking minimum 7degree of draft angle because our die should not get damage and we should get a finish good product. In some area we cannot avoid negative draft. So bending operation is provided for the manufacturing process, because deep drawing cannot be done at the negative draft area.

Tooling Direction for Plastic Part

Tooling direction is main consideration for plastic part and mold parts because it defines movement of mold part and possibility of plastic part to come-out from mold part (Core and Cavity).

Tooling Direction:-

In Molding machine arrangement is given to open the mold along a direction which is known as Tooling Direction.

In other words. The mold is built from two separate halves (Core and Cavity) and tooling direction basically define the direction of mold pulls apart.

Tooling direction is known as primary direction.

WHAT IS CLASS A, B, C SURFACES ?

Class A:- Styling or A class surface are the terms used in plastic product design. That means the surface of a component that is smooth (aesthetic) or visible side to the human eye after the part is assembled.

Class B:- It is an engineering surface, and it gives you thickness from class A surface

Class C:- when Class A and Class B surfaces are joined along the tooling axis it is called class C surface.

WHAT IS DOG HOUSE ?

Dog house is an engineering feature used in plastic trim design. Dog houses are used as supporting feature. Sometimes other engineering features like snaps; locators etc. are mounded on them to increase their strength. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity. Dog house and other engineering components are built on B-surface.

CONDITION FO DOG HOUSE

"C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• The height of ( B ) should be between 3.0 – 6.0 mm

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FIRST STEP IS TO CHECK THE CLASS A SURFACW WETHER THERE IS GAP OR NOT HERE WE HAVE A LITTLE GAP USE JOIN COMMAND AND INCREASE THE LIMIT TO 0.003 EVEN THEN THERE IS GAP SOTHEN,

USE JOIN COMMAND THEN SUB ELEMENT TO REMOVE AND AND REMOVE THE ONE SURFACE

AND THEN EXTRACT THE SAME SURFACE.

EXTEND THE BOTH THE SURFCES AND THEN DO UNTRIM AS SHOWN IN ABOVE FIGURE.

TOOLING AXIS

FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .

THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.

FOR CLASS B SURFACE USE THE OFFSET COMMAND. THE OFFSET IS DONE AT 2.5MM

SOME PATACHES CAN BE SEEN THIS PATCHES CAN BE REMOVED BY SIMPLYING USING MULTISECTION .

HERE FOR THIS PATCH I TRIED TO USE MULTISECTION BUT IT WAS NOT POSSIBLE I USED EXTRACR AND EXTROPOLATE EVEN IT WAS NOT POSSIBLE SO I USED FILL COMAND WHICH SHOULD NOT BE USED BUNT ONLY AT SMALL SECTION AND AT RARE CONDITION.

HERE FOR CLASS C SURFACE I USED SWIPT COMAND WITH DRAFT DIRECTION HERE I USED HIGH LENGTH BECAUSE IT WILL BE ABLE TO TRIM IN 1 SHOT.

THIS SMALL PORTION IS SWIPT WITH THE REFRENCE SURFACE FIRST OPTION.

HERE THIS PORTION IS TO BE JOIN WHICH IS HORIZONTAL AND VERTICAL USE MULTISECTION OVER HERE THEN EXTEND.

EXTENDED CLASS B

CLASS B IS TO BE EXTEND SO THAT IT SHOULD TRIM WITH CLASS C SURFACE

SOME OF THE PORTION IS NOT EXTENDED SO EXTRACT THE SURFACE UNTIM IT AND THE EXTROPOLATE IT AND USE THE EDGE OF THE CLASS B TO SPLIT THAT SURFACE.

FINALLY CLASS A , CLASS B AND CLASS B TRIM AND JOIN .

AFTER EXTtending burface and c surface will trim ALL OF THEM TO CRERATE CLOSE BODY.

THIS IS HOW CLASS A AND CLASS C SURFACE LOOK WHEN JOIN.

TO CHECK WETHER THIS SURFACE IS FULLY JOIN USE BOUNDRY COMAND WHEN IT SHOWS THIS MESSAGE MEANS IT IS CLOSED SURFACE.

FOR CREATING THE FLANGES I EXTRACTED THE MASTER SECTION AND THE EXTRACTED THE SURFACE EDGE THEN USE SWEEP.

DIVIDED THE SWEEP INTO PEACES AND CREATED CLOSE BODY AND THEN USE CLOSE SURFACE.

USE HOE COMMAND TO CREATE HOLE AND PROVIDED FILLET AXIS IS CREATED ON SIRFACE WHICH WILL HELP LATER WHEN HEAT STAKE WILL BE PLACED.

DRAFT ANALYSIS

THE FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE

DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.

THERE IS BLUE COLOUR WHICH WILL BE THERE BECAUSE THAT IS THE BEND AREA.

• DRAFT ANALYSIS IS DONE ON FINAL BODY FOR NOW IGNORE THE FLANGES BECAUSE IT IS WILL HAVE DIFFERENT DIFFERENT TOOLING AXIS.
• DRAFT ANALYSIS IS DONE ON THE SOLID BODY HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE.
• THE BLUE COLOR MEANS THE DRAFT ANGLE IS NEGATIVE DEGEE WHICH IS MANDATORY FOR THE SOLID BODY BASE SIDE.
• THERE ARE SOME RED PORTION WHICH IS ON A SURFACE THE A WHICH WILL COME AT SOME PORTION.
• RED LINES ARE OF FILLETS WHICH IS ACCEPTABLE.
• WHEN THE DRAFT ANGLE IS 2.9 SOME OF THE ARE GETS GREEN WHICH IS ACCEPTABLE.BUT WITH 2.7 THERE IS NORED COLOR
• THE RED COLOR IS COMING BECAUSE IT IS VERTICAL PORTION.

HER USED SECOND TOOLING AXIS FOR DRAFT ANALYSIS.

SECOND

HERE THE ABOVE FIGURE IS THE CLASS A SURFACE IN WHICH INNER PORTION IS TO BE VISIBLE SO I NEED TO OFFSET IT TO OPPOSIT SIDE FOR THE CLASS A SURFACE.

FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .

THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.

CLASS B SURFACE

CLASS C SURFACE FOR THIS I USED SWIP COMMAND WITH RESPECTIVE TO SURFACE OPTION AND PROVIDED 90 DEGREE DRAFT BECAUSE THE EDGES ARE PRTPENDICULAR TO THE TOOLING AXIS.

FOR FLANGES USED EXTEND COMAND AND EXTENDED THE EDGES AND OFEST IT THEN USED TRIM COMMAND TO KEEP THE REQUIRED SURFACE AFTER THAT THICKEN COMMAND IS USED TO THICKEN THE SURFACE AND UNITRIM THE THICKEN FLANGE

AFTER UNITRIM USED HOLE COMMAND TO CREATE HOLE.

FINALL SOLID BODY AXIS IS CREATED ON THE HOLE BECAUSE SO THAT IT WILL HELP TO TRANSFER THE HEAT STAKE ON THE EXACT LOCATION.

THE FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE

DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.

THERE IS RED COLOUR WHICH WILL BE THERE BECAUSE THAT IS THE HORIZONTAL SURFACE.

FINAL DRAFT ANALYSIS ON THE MAIN BODY.

THIRD

CLASS A SURFACE

FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .

THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.

AFTER OFSETTING CLASS B SURFACE THERE ARE SOME PATCHES THIS PATCH IS RESOLVED BYUSING MULTI SECTION.

CLASS C SURFACE FOR THIS I USED SWIP COMMAND WITH RESPECTIVE TO SURFACE OPTION AND PROVIDED 90 DEGREE DRAFT BECAUSE THE EDGES ARE PRTPENDICULAR TO THE TOOLING AXIS.

FOR CREATING FLANGE FIRST EXTRACT THE MASTER SECTION THEN EXTRACT THE EDGE THEN USED SWIPT COMMAND AFTER OFSET THE SURFACESS TO CREATE PART OF IT THEN TRIM AND THEN USED CLOSE BODY COMMAND.

FINAL BODY

FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE

DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.

THERE IS NO RED OR BLUE COLOR ON THE SURFACE MEANSE TOOLING AXES IS CORRET.

• DRAFT ANALYSIS IS DONE ON FINAL BODY FOR NOW IGNORE THE FLANGES BECAUSE IT IS WILL HAVE DIFFERENT DIFFERENT TOOLING AXIS.
• DRAFT ANALYSIS IS DONE ON THE SOLID BODY HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE.
• THE BLUE COLOR MEANS THE DRAFT ANGLE IS NEGATIVE DEGEE WHICH IS MANDATORY FOR THE SOLID BODY BASE SIDE.
• THERE ARE SOME RED PORTION WHICH IS ON A SURFACE THE A WHICH WILL COME AT SOME PORTION.
• RED LINES ARE OF FILLETS WHICH IS ACCEPTABLE.
• WHEN THE DRAFT ANGLE IS 2.9 SOME OF THE ARE GETS GREEN WHICH IS ACCEPTABLE.BUT WITH 2.7 THERE IS NORED COLOR
• THE RED COLOR IS COMING BECAUSE IT IS VERTICAL PORTION.

SECON TIME TOOK 0.45 DEGREE FOR THE HEAT STAKE AND FOR THE LOCATER.

FOURTH

CLASS A SURFACE

FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .

THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.

CLASS B AND C SURFACE WHEN ARE INTERSECTING WITH EACH OTHER SO THAT WE CAN TRIM IT.

FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE

DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.

THERE IS NO RED OR BLUE COLOR ON THE SURFACE MEANSE TOOLING AXES IS CORRET.

• DRAFT ANALYSIS IS DONE ON FINAL BODY FOR NOW IGNORE THE FLANGES BECAUSE IT IS WILL HAVE DIFFERENT DIFFERENT TOOLING AXIS.
• DRAFT ANALYSIS IS DONE ON THE SOLID BODY HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE.
• THE BLUE COLOR MEANS THE DRAFT ANGLE IS NEGATIVE DEGEE WHICH IS MANDATORY FOR THE SOLID BODY BASE SIDE.
• THERE ARE SOME RED PORTION WHICH IS ON A SURFACE THE A WHICH WILL COME AT SOME PORTION.
• RED LINES ARE OF FILLETS WHICH IS ACCEPTABLE.
• WHEN THE DRAFT ANGLE IS 2.9 SOME OF THE ARE GETS GREEN WHICH IS ACCEPTABLE.BUT WITH 2.7 THERE IS NORED COLOR
• THE RED COLOR IS COMING BECAUSE IT IS VERTICAL PORTION.

SECON TIME TOOK 0.45 DEGREE FOR THE HEAT STAKE AND FOR THE LOCATER.

SOME PORTION OF THE DOG HOUSE AND HEAT STAKE ARE LOOKING BLUE BUT IT IS OK BECAUSE WHEN WE WILL REVERSE THE DIRECTION IT WILL TURN RED.

HOW DID I PLACE THE HEAT STAKE EXACTLY ?

IN ASSEMPLY SECTION I USED AXIS TO AXIS TRANSFER OPRION AND TRANSFER IT TO THE AXCES CREATED WIN THE INDIVIDUALL FILES.

FINAL ASSEMBLY

THANK YOU