Week 11 - Final project

A) - ARM-REST TOP

1- This is the input A surface of the arm rest top . 

2- We now create tooling axis by extracting the surface and extrapolating it , then we will place a point on it and add a line with reference to the surface.

 

3- We will now create B-surface , we will directly offset the A surface with a thickness of 2.5 mm . 

5- We wil create flange on A surface, we will extract some boundary from A surface and then use the sweep tool to create flange . we will create sketch for flange, then we will extract it and extrude it such that it passes through the sweep . we will use split tool to create the flange. we will then join it to the A surface.

6- We will offset the flange with 2.5mm , then we will join these flanges with the B surface.

7- We will create side core axis for the flange , we will extract the face of flange and add a point to it and then add a line to it , this will be our side core axis .

8 - We will create C surface by using sweep tool and multisection surface tool on flanged A surface . we will join the C surface with the flanged A surface .

9- We will now trim the C surface with the flanged B surface . this will give us our closed surface .we will use the closed body tool from part desugn workbench to convert the surface into solid .

10 - We will create the heatstake clearance on the flanges , this clearance will allow the heatstake to fit in it . we will create a sketch for clerance and pad it such that it passes through the flanges , now we will copy and translate it to rest of flange , we will then use the remove command to remove the clearance body from main body , this will give us our clearance hole . 

11 - This is the detail tree structure of the ARM REST TOP .

 

12 - DRAFT ANALYSIS ON ARM REST TOP . 

13 - Draft analysis is done on A side surface in main tooling axis direction , we can see that the surface clears in the main tooling axis .

14 - Draft analysis is done on B side surface in main tooling axis direction , we can see that it clears in the main tooling axis .

15- Draft analysis is done on flange in side core axis direction . we can see that the flange clears in side core axis direction . 

B) -  ARM REST BOTTOM A - SURFACE .

16 -This is the A surface for the arm rest bottom .

17 - We will create tooling axis by extracting the base face , then we will add a point on the face . we will add the line with reference to the point and surface .

18 - We will create B surface , we will extract the faces and then untrim the faces. we will offset it by 2.5mm and then we will trim it together to get the B surface . we will apply fillet to it . 

19 - We wil extract the boundary from A surface and then sweep it . we will sketch the flange , and then extrude it such that it passes through the flange . we will use split tool to get the required flange . we will add the flange to the A surface .

20 - We will create side core axis by extracting the face from wall of A surface , we will add a point to the surface and then we will add a line with reference to the surface and point . 

21 - We will offset the flange by 2.5mm , we will then trim this offsetted flange to the B surafce . 

22 - We will create C surface from flanged A surface by using sweep tool and multi section surface tool . we will join the C surface to the A surface .

23 - We will trim this surface with the flanged B surface .  we will get the closed surface . now we will use the closed body tool from the part body workbench to create the closed body . 

24 - Now we will create heatstake , we wil extract the face and add a point on the surface . we will draw the sketch of heatstake and pad it such that it passes through the body and then we will use the union trim tool join the heatstake to the main body .

25 - We will create heatstake clearance on the flange, we will draw the sketch of clearance and pad it such that it passes through the flange . we will then use the remove tool to remove the pad from the main body ,  this will give us our heatstake clearance . 

26 - Detail tree structure 

27 - Draft analysis on ARM REST BOTTOM 

28 - Draft analysis on a side surface in main tooling axis direction , it can be seen that it clears in the tooling axis . only the inside face does not clear in the main tooling axis . 

29 - Draft anlaysis is done on B side surface  in main tooling axis direction . we can see that every face clears except the curved face  . 

30 -  Draft analysis is done on the inside face in the side core axis direction . we can see that the faces which did not clear in main tooling axis now clears in side core axis direction . 

C - MAP POCKET  TOP 

31 - This is the A surface of the map pocket top . 

32 - We will create tooling axis by extracting the face and add a point on the surface , we will add a line with reference to the surface and point .

33 -We will create B surface by extracting the faces from the A surface , then we will untrim the surfaces . we will offset it with 2.5mm and trim it together . this will give us our B surface , we will add required fillet to the surface .

34 - Now we will create flange on A surface , we will extract the boundary and sweep it . we will draw sketch of flange and extrude the sketch such that it passes through the sweep .  we will use the split tool to get the flange . we will add this to the A surface .

35 -  We will offset the flange by 2.5mm and then we will join it with the B surface .

36 - We will create C surface by using sweep tool and multi section surface tool on the flanged A surface . we will then join the sweep with the flanged A surface . 

37 - Now we will trim this surface with the flanged B surface , this will give us our closed surface . we will used the closed body command to create the body from the closed surface .

38 -  We will create heatstakes , we will extract the surface and point on it for position of heatstakes .  now we will sketch the heatstake and pad it such that it passes through the body . we will give draft of 0.5 degree to the heatstake  .  we will copy the heatstake and position it on the points . now we will use the union trim the heatstakes with the body . 

39 - We will create heatstake clearance on the flange .  we will draw sketch of clearance hole and pad it such taht it passes through the flange . we will copy the pad and position it on the points . we will use the remove tool to remove the pad from the main body this will give us our clearnce hole on flange . 

40  - We will create doghouse , we will sketch for doghouse and sweep it in the tooling axis direction in draft of 1.5 degree . we will offset the base to height of 20mm and then trim it with the sweep . we will use the thick surface tool from part workbench to create the doghouse body . 

41 -  We will create sink well for the doghouse , first we will offset the sweep with 1mm and then offfset the base with 4 mm , we will trim it together , now we will split the body with the trimmed surface . 

42  - we will create a lifter axis for the doghouse and then apply a draft of 0.5 degree to the inside faces of the doghouse . we will add the required fillet . 

43 - We will now create pushpin , we will create the sketch the pushpin and then use the shaft tool to create the pushpin . we will now join the doghouse with the puspin .

44 -  Now we will union trim the doghouse and pushpin with the main body . 

45 - Detail tree structure 

46 -  DRAFT ANALYSIS ON MAP POCKET TOP.

47- Draft analysis on A side surface in main tooling axis direction . we can see that it clears in main tooling axis direction .

48 - Draft analysis on B side surface in main tooling axis direction , we can see that the b side clears in main tooling axis direction . 

49 - Draft analysis on doghouse and heatstake in main tooling axis direction , we can see that it clears it in the main tooling axis . 

50 -  Draft analysis on doghouse inside faces in lifter axis direction .  we can see that it clears it in the lifter axis direction .

D ) MAP POCKET BOTTOM 

51 - This is the A surface for the map pocket bottom  . 

52 - We will create tooling axis by extracting the surface and untrimming it . we will add a point on the surface and add a line with reference to the surface and point . 

53 - We will create B surface by extracting the faces of the A surface and then untrimming it and offsetting it by 2.5mm . then we will trim the offsetted surfaces together this willl give us B surface . we will apply required fillet to it . 

54 - We will create flange by extracting boundary and then sweeping it ,  we will sketch the flange and then extrude it such that it passes through the flanges. we will split the sweep with the extrude . now we will join the split with the A surafce . 

55 - we will offset the flange by 2.5mm and trim it with the B surface .  this will give us our flanged  B surface . 

56 - We will create C surface by using sweep tool and multisection surface tool with reference to flangedA surface ,  we will join the C surface with the flanged a surface .

57 - We will trim this surface with the flanged B surface . this will give us our closed surface . we will used the closed body command from part workbench toconvert the closed surface to the body . 

58 - We will create heatstake clearance for the flange , we will draw sketch for the clearance and pad it such that it passes through the flange . we will copy and position it onto rest of the flanges .  we will then remove the pad from the main body using remove tool . this will give us our clearance hole . 

59  - Detail tree structure . 

60  - DRAFT ANALYSIS ON MAP POCKET BOTTOM . 

61 - Draft analysis on A side surface in main tooling axis direction . we can see that the A side clears in main tooling axis .

62 -  Draft analysis on B side surface in main tooling axis direction .  we can see that B side surface clears in main tooling axis direction . 

E) LOWER SUBSTRATE 

63 -  This is the A surface for the lower substrate . 

64 - We will create tooling axis by extracting the surface and adding a point onto the surface ,  we will add a line with reference to the point and the surface . 

65 - We will create B surface by offsetting the A surface with 2.5mm thickness .

66 -  We will create flange for the A surface .we will join  this flange to the A surface .

67 - We will offset the flange by 2.5mm thickness and trim this to the B surface . this will give us our flanged B surface . 

68 - We will create C surface by using sweep tool and multisection surface tool . we will then join this C surface with the a surface  . 

69 -  We will trim this surface with the flanged B surface ,  this will give us our closed surface. we will use the closed body command from part workbench to convert the closed surface into body . 

70 - We will create heatstake by extracting surface and adding points onto the surface for the position of heatstakes .  we will sketch the heatstake and pad it such that it passes through the flange, then we add a  draft of 0.5 degree to the heatstake .  we will copy and position the heatstakes onto the points. then we will use the union trim command to join heatstakes to the main body .  

71 - We will create doghouse . we will first draw sketch and sweep it in tooling axis direction with 1.5 degree . we will offset the base to a height of 20mm . then we will trim it with the sweep .  then we will thicken this trim . 

72 - We will offset the sweep awith 1mm also we will offset base with 4mm we will trim the offset together , then we will split this trim from the doghouse body . this will create the sink saver . we will create lifter axis and add draft to the inside faces of the doghouse with o.5 degree . we will apply fillet to the doghouse . 

73 - We will create sketch of pushpin and then use the shaft tool to create the pushpin . we will add this pushpin to the doghouse. similarly we will create another doghouse and pushpin . 

74 - We will union trim this doghouse and pushpin to the main body . 

75 -  Detail tree structure . 

76 - DRAFT ANALYSIS OF LOWER SUBSTRATE .

77 - Draft analysis on A side surface in main tooling axis direction . we can see that it clears in main tooling axis direction . 

78 - Draft analysis on B side surface in main tooling axis direction . we can see that b side surface clears in main tooling axis direction . 

79 - Draft analysis on heatstakes and doghouse in main tooling axis direction . we can see that the heatstakes and doghouse clears in main tooling axis direction .

80 - Draft analysis on inside faces of doghouse in lifter axis direction .  we  can see that the inside faces of doghouse clears in lifter axis direction . 

F) FRONT DOOR PANEL ASSEMBLY .

1- This the assembly of all the parts . 

2 - This is the arm rest top with locating points . 

3 - This is the arm rest bottom with locating points . 

4 -  This is the map pocket top with locating points . 

5- This is map pocket bottom with locating points . 

6 - This is lower substrate with locating points .

7 -  Arm rest top will connect to Arm rest bottom with the heatstake as shown below .

8 - Arm rest will connect to the lower substrate as shown below . 

9 - Map pocket top will connect to map pocket bottom as shown below . 

10 -  Map pocket will connect to the lower substrate as shown below . 

11 - Below is final assembly of the parts .