Week 11 - Final project

Report for this final project are as follows :-

First the given Door trim class A surface is seperated in four sub segments, i.e Arm Rest, Lower substrate, Map pocket and Bottle holder. Than for individual parts tooling axis is defined.

Tooling axis creation.

• At first tooling axis is to defined to perform draft analsys on given class A surface for each part.
• The given A surface is analysed and tooling axis is defined in Y direction.
• A point is marked on the given class A surface and a line is created in Y direction
• With the help of the line a line is created and named as axis tool.

Draft Analyses results :-

Arm Rest - Draft analsys shows green colour in Y direction on the given A-surface which indicates the surface can be drafted for upto 3 degees, than same is done in z direction. The screenshots are attached belows.

For Arm Rest tool axis is created in both Y direction and z direction because it is not possible to clear draft in single direction.

lower substrate - Draft analsys shows green colour on given class A which indicates it can be drafted to 3 degrees and blue colour in the opposite side which shows draft is less than 3 degrees.

Map Pocket - Over all green colour is observed which shows it can be drafted to 3 degrees.

Bottle holder - Draft analsys show green colour on given class A and blue patches in the bottom which indicates that the draft is less than 3 degree on few faces. over all green colour is observed whic shows 3 degrees draft.

After Draft analsys, B surface creation is proceeded :-

• At first given A-surface is offseted to 2.5mm as specified.
• Than the patches are identified and extracted which were left after offset.
• Than boundary is taken on the part left after offset and with the help of mutisection command, patch is fixed and than joined with the main surface.
• The body is than extraploated for extra 2mm.

Creation of C surface is done after B surface.

• Boundry is taken on the given A-surface.
• On the marked boundry with the help of sweep command surface sweep is created with reference to surface and markded angle is 97.5 degree, length of the sweep is kept 5mm.
• Same operation is carried out on all edges of the A surface and than joined together to obtain C surface.
• After A and C joined together, B surface is extrapolated so that it can be trimed with the joined (A and C) surface.
• After triming the obtained body is than made closed body with the help of close surface command in surface workbench.

Draft analsys is performed on the B-surface body which shows green colour that indicates the obtained surafce can be drafted upto 3 degress and blue colour indicates that the draft is less than 3 degress.

Dog House creation :-

• A point is marked on the lower substrate for dog house creation.
• On the marked point a plane is defined in zx direction.
• On the defined plane with the help of positioned sketch dog house sketch is created of dimension, 30x30mm height and width, wall thickness 2.5mm, edge fillet 1.5 mm outside, base coring is between 3 - 6mm.
• Than rib sketch is crated on the same marked plane and padded to the required dimension.
• Draft of 1.5 degree is given to the outer faces and 0.5 degree to inner faces.

Tooling axis for dog house :-

• On the marked point a plane is defined in xy direction and a line is created normal to surface.
• The line created is marked tool axis for the dog house
• On the defined tooling axis draft analsys for Dog-house is performed.

Draft analsys for Dog-house as attached in the figure show green colour on outer faces that indicates the faces can be drafted to 1.45 degrees. Inside faces also shows green colour which indicates the inner faces can be drafted to 0.45 degrees.

For Heat stakes and locators creations :-

• From given master section heat stakes dia is measured.
• On the extracted surface and marked point plane is defined.
• On the defined plane using positioned sketch two circles of dia 4.5mm, and 7.5 mm are drawn for heat stakes.
• The drawn sketch is padded and drafted for 0.5 degree and edge fillet given of 0.25mm and height 30mm. on the same point support ribs are drawn for the heat stakes and padded for 1mm thickness and given draft for 0.5 degree.
• Now using point to point translate option the heat stakes are translated to all the marked points on the surface and than added to the main body.
• Than again a point is taken on the surface to form 4 way locators. sketch of 20mm x 20mm is drawn and paded to thickness of 1mm and than draft is given for 0.5 degree, chamfer 2mm, height 35mm, edge fillet given 0.25mm.

Draft analsys is carried out for heat stakes and it shows green colour, which show it can drafted for 0.5 degrees.

Flanges Creation :-

• To create flange the given master section is analysed and with the given dimension multiextract is taken for the flange sketch.
• A plane and point is created and isolated in yz plane to perform sketch of the desired flange. The multiextract is then isloated to make it independent sketch.
• A intersect is taken between the B-surface face and plane where plane has to be created.
• With the intersect, flange sketch is made coincidence, so that the flange will start from the edge of the B-surface.
• The drawn sketch is than padded in part workbench for required thickness (2.5mm) and edge fillet (0.5mm) and draft (0.5 degree) is provided to its faces.
• Same operation is performed for the other flanges and counter sink hole is provided on the flanges for the heat stakes.

Finally push pin is alligned with the axis of the Dog house, lower substrate is fixed and face contrains in applied between push pin and dog house upper face and updated to obtain the desired assmbly.

Thankyou