Week 11 - Final project
Aim:
To Create the lower substate component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
Objective :
- To design lower substate as per automotive OEM Standard.
- Create B Class and C Class and tooling axis.
- Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
- Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
- Creating Engineering Features.
Operations :
- Creating tooling axis.
- Create draft analysis
- Creating Class B surface.
- Creating Class C surface.
- Final product using closed surface.
- To create heat stakes, locators and dog house.
MATERIAL USED :
Acrylonitrile butadiene styrene(ABS)
Door trim is manufactured in plastic materials such as ABS. ABS plastic remains hard, rigid and tough even at low temperatures. It is available in fire-retardant, heat-resistant and platable grades. It is found inside the car.
Tooling Axis:
Tooling Axis is created on the surface along which a point is created on the centre of the surface and a line is extruded along the y is which is normal to the surface. The tooling axis determines the direction of the core and cavity moves.
Class A surface:
Class A surface is a any set of freefrom surface of high efficiency and quality. It is the aesthetic surface of any automotive component. class A surface is visible to eye .It is given as input to design the Class B&C surfaces.
Draft analysis class A:
From draft analysis, we can verify draft angles, examine the angle changes within a face, as well as locate parting lines, injection and ejection surfaces in parts.
It is an important feature in Catia which helps the user to analyse the draft on various surfaces. The draft analysis toolbar provides two modes for analysis of the draft, first is the quick analysis which basically has three colours (green, red, and blue) for analysing on the other hand other option is the full analysis mode which enables a few more details into the draft and is used in the complex components.
Draft for closed surface:
Class B surface:
Class B surface is invisible to the eyes or it is often found in back side of the Class A surface. It is mainley the thickness of the component and the thickness of the component is 2.5mm thickness.
Class C surface:
Class C surface connects the surface between Class A and B surface. This surface connects both A & B surfaces along the tooling axis. It is the thickness of the Class A&B surface.
A & C join:
Engineering Features:
DOG HOUSE: It is an engineering feature used in plastic trim design. It is used as a supporting feature. By using dog house, we can support the other engineering features like heat stakes, screw boss and locators to locate them at a certain height where we cannot violate the design rules for the features. By using doghouse, we can avoid sink marks in class A 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.
Flanges:
Flanges are supporting element that gives strength to heat stakes.
Final Product:
Tree structure:
DOOR ARMREST:
Aim:
To Create the Door Armrest component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
Objective :
- To design lower substate as per automotive OEM Standard.
- Create B Class and C Class and tooling axis.
- Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
- Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
- Creating Engineering Features.
Operations :
- Creating tooling axis.
- Create draft analysis
- Creating Class B surface.
- Creating Class C surface.
- Final product using closed surface.
MATERIAL USED :
Acrylonitrile butadiene styrene(ABS)
Door trim is manufactured in plastic materials such as ABS. ABS plastic remains hard, rigid and tough even at low temperatures. It is available in fire-retardant, heat-resistant and platable grades. It is found inside the car.
Tooling Axis:
Tooling Axis is created on the surface along which a point is created on the centre of the surface and a line is extruded along the y is which is normal to the surface. The tooling axis determines the direction of the core and cavity moves.
Class A surface:
Class A surface is a any set of freefrom surface of high efficiency and quality. It is the aesthetic surface of any automotive component. class A surface is visible to eye .It is given as input to design the Class B&C surfaces.
Draft analysis class A:
From draft analysis, we can verify draft angles, examine the angle changes within a face, as well as locate parting lines, injection and ejection surfaces in parts.
It is an important feature in Catia which helps the user to analyse the draft on various surfaces. The draft analysis toolbar provides two modes for analysis of the draft, first is the quick analysis which basically has three colours (green, red, and blue) for analysing on the other hand other option is the full analysis mode which enables a few more details into the draft and is used in the complex components.
Side Core Draft analysis:
Draft for closed surface:
Class B surface:
Class B surface is invisible to the eyes or it is often found in back side of the Class A surface. It is mainley the thickness of the component and the thickness of the component is 2.5mm thickness.
Class C surface:
Class C surface connects the surface between Class A and B surface. This surface connects both A & B surfaces along the tooling axis. It is the thickness of the Class A&B surface.
A & C JOIN:
Flanges:
Flanges are supporting element that gives strength to heat stakes.
Final Product:
Tree Structure:
MAP POCKET:
Aim:
To Create the map pocket component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
Objective :
- To design lower substate as per automotive OEM Standard.
- Create B Class and C Class and tooling axis.
- Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
- Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
- Creating Engineering Features.
Operations :
- Creating tooling axis.
- Create draft analysis
- Creating Class B surface.
- Creating Class C surface.
- Final product using closed surface.
Tooling Axis:
Tooling Axis is created on the surface along which a point is created on the centre of the surface and a line is extruded along the y is which is normal to the surface. The tooling axis determines the direction of the core and cavity moves.
Class A surface:
Class A surface is a any set of freefrom surface of high efficiency and quality. It is the aesthetic surface of any automotive component. class A surface is visible to eye .It is given as input to design the Class B&C surfaces.
Draft analysis class A:
From draft analysis, we can verify draft angles, examine the angle changes within a face, as well as locate parting lines, injection and ejection surfaces in parts.
It is an important feature in Catia which helps the user to analyse the draft on various surfaces. The draft analysis toolbar provides two modes for analysis of the draft, first is the quick analysis which basically has three colours (green, red, and blue) for analysing on the other hand other option is the full analysis mode which enables a few more details into the draft and is used in the complex components.
Draft analysis for class ABC:
Final Draft:
Class B surface:
Class B surface is invisible to the eyes or it is often found in back side of the Class A surface. It is mainley the thickness of the component and the thickness of the component is 2.5mm thickness.
Class C surface:
Class C surface connects the surface between Class A and B surface. This surface connects both A & B surfaces along the tooling axis. It is the thickness of the Class A&B surface.
Engineering Features:
DOG HOUSE: It is an engineering feature used in plastic trim design. It is used as a supporting feature. By using dog house, we can support the other engineering features like heat stakes, screw boss and locators to locate them at a certain height where we cannot violate the design rules for the features. By using doghouse, we can avoid sink marks in class A 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.
Dog House Draft:
Engineering Features
Heat Stakes:
Heat staking also known as thermoplastic staking is the process of joining two dissimilar materials together. In heat staking we use local heating and cooling to raise the temperature of plastic components and allow plastic reforming to be carried out.
Heat staking Benefits:
- Similar and dissimilar materials may be joined: metal to metal, plastic to plastic, metal to plastic
- Accurate control operating within a small process window
- Local heating resulting in no damage to surrounding materials
- Processing of glass-filled materials
- No mechanical vibration
- Many heat-stake shapes possible through custom designed tools
Flanges:
Flanges are supporting element that gives strength to heat stakes.
Final Product:
Tree Structure:
MAP POCKET WITH BOTTLE HOLDER:
Aim:
To Create the map pocket component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
Objective :
- To design lower substate as per automotive OEM Standard.
- Create B Class and C Class and tooling axis.
- Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
- Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
- Creating Engineering Features.
Operations :
- Creating tooling axis.
- Create draft analysis
- Creating Class B surface.
- Creating Class C surface.
- Final product using closed surface.
Tooling Axis:
Tooling Axis is created on the surface along which a point is created on the centre of the surface and a line is extruded along the y is which is normal to the surface. The tooling axis determines the direction of the core and cavity moves.
Class A surface:
Class A surface is a any set of freefrom surface of high efficiency and quality. It is the aesthetic surface of any automotive component. class A surface is visible to eye .It is given as input to design the Class B&C surfaces.
Draft analysis class A:
From draft analysis, we can verify draft angles, examine the angle changes within a face, as well as locate parting lines, injection and ejection surfaces in parts.
It is an important feature in Catia which helps the user to analyse the draft on various surfaces. The draft analysis toolbar provides two modes for analysis of the draft, first is the quick analysis which basically has three colours (green, red, and blue) for analysing on the other hand other option is the full analysis mode which enables a few more details into the draft and is used in the complex components.
Final Draft:
Class B surface:
Class B surface is invisible to the eyes or it is often found in back side of the Class A surface. It is mainley the thickness of the component and the thickness of the component is 2.5mm thickness.
Class C surface:
Class C surface connects the surface between Class A and B surface. This surface connects both A & B surfaces along the tooling axis. It is the thickness of the Class A&B surface.
CLASS AC JOIN:
Final Product:
Tree Structure:
Final Finished product: