Week 11 - Final project

The operation to do:

1. Open all the inputs in assembly workbench.
2. Create Individual Tooling Axis.
3. Create Individual Draft Analysis for Class A Surface.
4. Create Individual Class B Surface.
5. Create Individual Class C Surface.
6. Create Individual Draft Analysis for the Overall Surface.
7. Create Individual Closed Surface.
8. Create Flanges with the given mastersection. 
9. Create Heat Stakes with given mastersection.
10. Insert extra Heat Stakes and Flanges where ever it is necessary.

Main moto of the project:

• Is to create Door panel

The Parts to be create:

1. Lower Substate
2. Door Arm Rest
3. Map Pocket
4. Map Pocket with bottle holder.

The material used in those surface are :

• Acrylonitrile Butadiene Styrene (ABS).

• Polypropelene.

Why those materials are used?

• ABS has a low melting point, enabling its easy use in injection molding and 3D printing. It also has high tensile strength and is very resistant to physical impacts and chemical corrosion, which allows the finished plastic to withstand heavy use and adverse environmental conditions.
• High dimensional stability (Mechanically strong and stable over time)
• The high surface brightness and excellent surface aspect.

Where it is used?

• It is used in car doors.

Followed Constraints:

• The change in dimension of the Class A Surface is not allowed.
• Change in thickness is not allowed.
• The thickness given to all the part is 2.5 mm.

Engineering Features followed in this Project are:

HEAT STAKES:

• Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. It is also known as permanent joining method. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out. This reforming can be used in a wide variety of applications. IT consist of ribs.

Guidelines to create Heat Stakes:

1. Height of the heat stake consist of. Rib height - (3 - 6 mm); Counterpart height - (>= 2 mm ); Staking part - (12 mm).
2. Inner dia - 5 mm
3. Outter dia - 7 mm
4. Depth of inner Dia - (2.5 - (0.5 t))
5. Total width of rib - 22 mm
6. Draft angel - 0.5 deg
7. Fillet radius - (0.5 mm)

                                                                        Heat Stakes

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 house wall thickness at intersection of part wall (c) should be 40% or less than main wall stack (T). 

Guidelines to create Dog House:

1. Width of the DogHouse - (25 - 35mm).
2. Height of the Dog House - (45 - 60mm).
3. Outter Draft - (> 0.3 deg), Nominal = 1.5 deg.
4. Inner Draft -  (> 0.1 deg), Nominal = 0.5 deg.
5. Thickness - Nominal Wall thickness.
6. Height of the Sink mark cut - (3 - 6mm).
7. Fillets can be given according to the thichness rule. 
8. Width of one dog house to another dog house is (w x 3).

                                                                      Dog House

Flanges:

Flanges are used with heat stakes for permenanet joint with another part. Flanges are also added strength to the part.

                                                                         Flanges

Tooling Axis:

• The tooling axis for this component will be created from the Y component. This should be done using the method of extracting the plane surface and Creating a point in the plane using a point on the surface. And finally, the line should create using the normal surface.

1) Lower Substate

2) Door Arm Rest with Main Tooling Axis

Door Arm Rest with side core Tooling Axis

3) Map Pocket

4) Map Pocket with Bottle Holder

Class A Surface:

• Class A Surface is a scanned model or the model which is already drawn is given for further process. It describes the final production surface data for the aesthetic parts of the car. The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modeling. This is the outer layer of the model.
• Class A surface is created from the .igs part file. We have to join the model in the file to create a class A surface.

1) Lower Substate

2) Door Arm Rest

3) Map Pocket

4) Map Pocket with Bottle Holder

Class B Surface:

• This is the surface followed by Class A Surface. It is the inner surface of the model with some thickness. The fillet and offset of the Surface should be given according to the Class A model. The flash from the molding process should not come into the surface of Class A, so the Class B design should not disturb the class A Surface.

1) Lower Substate

2) Door Arm Rest

3) Map Pocket

4) Map Pocket with Bottle Holder

• We have to create an overall offset for this ,. After this, we need to do multi section  for the patched surface to create the closed surface for class B.

Class C Surface: 

• Class C Surface is the surface that joins both class A & B using the boundary, trim, join method. The Class C finish allows more imperfections than Class A or B. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces that the Customer feels do not need to meet a high cosmetic.

1) Lower Substate

2) Door Arm Rest

3) Map Pocket

4) Map Pocket with Bottle Holder

• This Class C Surface is taken from the Reference of the Class A Surface. with an angle of 90 deg for the both Outter , surface and Window switch surface. The top shoud be given a angel of 3 deg.

Final Product:

• The final product includes the finished surface of Class A, Class B, and Class C. Having the complete surface model.

1) Lower Substate                         

2) Door Arm Rest

3) Map Pocket

4) Map Pocket with Bottle Holder

                                     

Draft Analysis:

• The draft analysis technique is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied. Here the part should get easily removed from the panel dies (in case of Sheet metal part) or Mold (in case of plastic). The analysis shows whether the angle given on the surface is up to the level or not. This can be identified by using Green, Blue, and Colour. Green means to perfect (< 2.9deg), Blue (0deg), and Red (> 2.9deg). These degrees will cange for engineering features.

1) Lower Substate

2) Door Arm Rest with Main Tooling Axis

Door Arm Rest with side core Tooling Axis

3) Map Pocket

4) Map Pocket with Bottle Holder

                                               DRAFT ANALYSIS OF CLASS A SURFACE

1) Lower Substate

2) Door Arm Rest with Main Tooling Axis

Door Arm Rest with side core Tooling Axis

3) Map Pocket

4) Map Pocket with Bottle Holder

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                                                   DRAFT ANALYSIS OF OVERALL SURFACE

1) Lower Substate

                                                      DRAFT ANALYSIS OF Heat Stakes

                                                    DRAFT ANALYSIS OF Inner Dog House

                                                     DRAFT ANALYSIS OF Outter Dog House

                                                        DRAFT ANALYSIS OF Flanges                         

Solid Surface:

1) Lower Substate

2) Door Arm Rest

3) Map Pocket

4) Map Pocket with Bottle Holder

Over all Door Panel with all parts connected together

                                                                  MULTI-VIEW

                                                                 Final Output

Tree Structure