Week 11 - Final project

AIM

To create a door interior part from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in catia v5

SOFTWARE USED

CATIA V5

OBJECTIVES

• Create a sketch by using Positioned sketch
• All the should be sketches should be Iso-Constrained
• Ensured Proper Tree Structure
• Geometrical sets should having a proper name based on the sketches present inside of it
• Create thickened part using master section for reference
• Create the mounting features as per design guidelines in the industry and with master sections
• Creating of Draft analysis & Tooling analysis
• Creation of parting lines and check tooling feasibility

INPUT OF CLASS A SURFACE

Since the input class A surface is containing four different parts(class A). So class b and c for all the surface has been created in separate catpart. Also performing draft analysis and tooling axis separately. finally all the surface have assembled together in one catproduct

CREATION OF TOOLING AXIS – LOWER SUBSTRATE

DRAFT ANLAYSIS

Draft analysis in catia is a command that is used to detect if the part you drafted will be easily removed from the mold. it is performed based on color ranges identifying zones on the analyzed element.

Most of the industries is using minimum draft angle is 3 degree

PROCEDURE

• Check all the boundary whether it has connected or not.
• Check the model visually & choose the best tooling direction which should be easy for draft.

• After analyzing the above model the best tooling axis is y direction.

CREATING THE TOOLING AXIS

• Create a point on centre of gravity of part by using measure inertia command and insert a axis system on the point as shown below

• create a point -direction line parallel to the y axis and named as TOOLING AXIS as shown below

CREATION OF TOOLING AXIS – BOTTLE HOLDER

PROCEDURE

• Check all the boundary whether it has connected or not.
• Check the model visually & choose the best tooling direction which should be easy for draft

• After analyzing the above model,we have to create tooling axis on Y

CREATING THE TOOLING AXIS

• Create a point 1 and insert a axis system on the point 1 as shown below

• Create a intersection on XY plane for the given surface

• Create a point to point line as shown below

• Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING X DRIECTION

• Create a intersection on ZY plane for the given surface

• Create a point to point line as shown below

• Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING Y DRIECTION

• Add bisecting line by the reference of tooling facing x direction and tooling facing y direction and named as tooling axis

CREATION OF TOOLING AXIS – ARMREST

PROCEDURE

• Check all the boundary whether it has connected or not.
• Check the model visually & choose the best tooling direction which should be easy for draft.

• After analyzing the above model, there is an chance for undercut when we consider tooling axis from z.so we have to create tooling axis on x,y and also z

CREATING THE TOOLING AXIS

• Create a point and insert a axis system on the point 1 as shown below

• Create a intersection on ZX plane for the given surface

• Create a point to point line as shown below

• Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING X DRIECTION
• Create a intersection on ZY plane for the given surface

• Create a point to point line as shown below

• Add bisecting line as shown below by the reference of two lines created above and named as TOOLING FACING Y DRIECTION
• Add bisecting line by the reference of tooling facing x direction and tooling facing y direction and named as tooling axis

CREATION OF TOOLING AXIS – UPPER SUBSTRATE

PROCEDURE

• Check all the boundary whether it has connected or not.
• Check the model visually & choose the best tooling direction which should be easy for draft.

• After analyzing the above model the best tooling axis is y direction.

CREATING THE TOOLING AXIS

• Create a point on centre of gravity of part by using measure inertia command and insert a axis system on the point as shown below
• create a point -direction line parallel to the y axis and named as TOOLING AXIS as shown below

• To perform draft analysis open customize view parameters and choose the material

• Insert a feature draft analysis by following these commands

I insert>analysis>feature draft analysis

• Align the compass on tooling axis that we created
• Open the color scale and enter the value is 3 deg.
• If the whole body is green that all the faces is greater angle than the provided angle

DRAFT ANALYSIS REPORT OF CLASS A – UPPER SUBSTRATE

DRAFT ANALYSIS REPORT OF CLASS A – BOTTLE HOLDER

CREATION OF CLASS B SURFACE

• Insert a new gemeotrical set.Measure the value of thickness in master section.The value is 2.5mm
• Offset the class A surface to 2.5mm.
• Check all the sub elements are formed if not try to fix it locally

LOWER SUBSTRATE CLASS B

DRAFT ANALYSIS REPORT OF CLASS A – ARM REST

DRAFT ANALYSIS REPORT OF CLASS A – LOWER SUBSTRATE

CREATION OF CLASS B SURFACE

• Insert a new gemeotrical set.Measure the value of thickness in master section.The value is 2.5mm
• Offset the class A surface to 2.5mm.
• Check all the sub elements are formed if not try to fix it locally

LOWER SUBSTRATE CLASS B

BOTTLE HOLDER CLASS B

ARMREST CLASS B

MAP POCKECT CLASS B

CREATION OF CLASS C SURFACE

• Analyse the class A once where the sweep is easier to create towards tooling direction
• Create a boundary using limitation points whereever possible for sweep

• Sweep the above boundaries for industrial standard 3 degree towrads tooling axis

LOWER SUBSTRATE CLASS C SURFACE

BOTTLE HOLDER CLASS C SURFACE

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ARMREST CLASS C SURFACE

UPPER SUBSTRATE CLASS C SURFACE

CREATION OF B SIDE ATTACHMENT FEATURES

DOG HOUSE

• Extract the surface that we going to create a dog house
• Insert a axis system. use positioned and draw a dog house sketch
• Sweep the sketch to 1.5 degree on the direction of main tooling axis

• Add thickness to the above sketch of 2.5mm by using thicken surface

Dog house rule

B=4mm

t=2.5mm

C=0.4 * t=1mm

• Extract the sweep and offset to b=4mm and c=1mm on all directions like the below
• Trim the portion to get the required sketch
• Draft to 5 degree along second tooling axis
• Add fillet to all faces
• Assemble the doghouse to lower substrate solid
• Translate the doghouse to wherever we nee
• To place pushpin on the doghouse create a ribs to doghouse
• Trim the ribs with doghouse

HEAT STAKES

Heatstakes is known as thermoplastic staking is the process of joining two dissimilar metals together

• Extract the surface that we going to create heat stake
• Use positiioned sketch and draw a heat stakes sketch

• Use pad commands for the sketch to till we required
• Draft the stakes minimum of 0.5 degree
• Add fillet 0.5mm o all faces
• Assemble the heat stake to lower subtrate solid

• Maintain a 50mm minimum between two heat stakes
• Translate the heatstakes to wherever we need
• Trim the all heat stakes with lowersubstrate solid

LOCATOR

• Extract the surface that we going to create locator
• Use positiioned sketch and draw a locator sketch

• Use pad commands for the sketch to till we required
• Draft the locator for minimum of 0.5 degree
• Add fillet 0.5mm o all faces
• Assemble the locator to lower subtrate solid

FLANGE

Create a flange for attachment of heatstakes and locators at lower substrate

PUSHPIN

• Draw a sketch of pushpin by using positioned sketch command
• Ensure that the sketch is iso constrained

• Shaft the sketch to 360 degree by using shaft command
• Add minimum fillets to pushpin

WEIGHT OF THE COMPONENT

• Apply material plastic to the product
• Use measure command to caluacute the weight of product

CALCUALTION

Lower substrate = 0.503kg

Bottle holder = 0.274kg

Arm rest = 0.145kg

Map Pocket = 0.172kg

The total weight of the product is =1.094kg

DRAFT ANALYSIS REPORT OF UPPER SUBSTRATE

DRAFT ANALYSIS REPORT OF BOTTLE HOLDER

DRAFT ANALYSIS REPORT OF ARM REST

DRAFT ANALYSIS REPORT OF LOWER SUBSTRATE

CREATION OF PARTING LINE

Parting line is used to the differentiate between core and cavity

NOTE = THE PARTING LINE BELOW IS CREATED WITHOUT ATTACHMENT

TREE STRUCTURE

DOOR INTERIOR

CONCLUSION

Thus the door interior part has been created from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in catia v5