Week 11 - Final project

1)CLASS A SURFACE :

• Class-A (or 'Strak') is a term used in specifically in automotive design. 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 modelling. This is because as it achieves the highest surface quality levels, and it demands a high level of automotive design knowledge as well as surface modelling skills.
• Class A represents the 'craftwork' end of the design process. Creating the main surface shapes to describe the vehicle is the primary design activity. But the painstaking, detailed craftsmanship of perfecting those surfaces, designing flanges and panel gaps is what guarantees that a beautiful design turns into a beautiful manufactured product.
• Here we have four class A surfaces as inputs:

2)TOOLING AXIS CREATION :

• Tooling axis plays important role in plastic product manufacturing and designing, this axis decides the direction in which mould is going to work while production of the component.
• The main focus while deciding the tooling axis is clearing the component in the moulding in the same axis with the minimum use of the side core for producing the component, the side core usually adds up to the cost of the component.
• For the particular component X,Y and Z can be the possible direction for the tooling axis.
• You must specify the axis system by creating the point on the surface.
• With the help of the intersect in the YZ plane create the tooling axis in YZ plane .
• With the help of the intersect in the ZX plane create the tooling axis in ZX plane.
• The last step is to bisect the two tooling axis to obtain the main tooling axis of the class A surface.

3)CREATING THE CLASS B SURFACE:

1. Class B surface is the surface which is created with the help of class A surface as the reference.
2. The the class B surface is the surface where all the necessary attachments and supports of the component is made .
3. The main parts without the edge fillets are extracted and untrimmed and then they are extrapolated for better view.
4. The extrapolated parts are then made offset with reference to the class A with the thickness of the component, here thickness of the component for base bracket is 2.5 mm.

4)CREATION OF CLASS C SURFACE AND TRIM :

• The class C surface is the surface which is created to provide thickness to the class A surface with the help of class B surface.
• The class C surface is the middle portion of the class A and class B surfaces.
• The class C is created with the help of the sweep command in surface workbench.
• The class A surface's boundary is taken as profile (guide curve) and then tooling axis created is taken as direction of the sweep in subtype draft direction
• The draft angle for the sweep is 3 degrees.
• The holes are created using the same axis and draft angle.
• The attained sweep is joined with class A surface to obtain the class C surface.
• The final trim is obtained by trimming the class B with the class C surface.
• The final check to ensure the proper clossness of surface with the boundary command .

5)CREATING THE CLOSED BODY AND ASSIGNING IT AS MAIN BODY

• Move to the part window and with the help of surface based feature close the surface to get the closed part body.
• Follow this for all the components.

6)CREATING THE ATTACHMENT FEATURES FOLLOWING THE MASTER SECTION.

#HEAT STAKES

• Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic.
• The process is to deform the plastic material using heat and force at a set process time.
• The bond is made by partially de-forming the plastic part in order to fix the other.
• Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such as automotive, IT and consumer appliances.
• 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.

#RIBS

• The ribs provide economical stiffness and strength to the part without increasing the overall thickness of the part.
• The ribs are used as locating and arresting in the assembly as locators.
• Proper allignment in mating parts, slot and rib pair is long lasting other than screw pair which loosen up with time.
• Acting as stops or guide for mating the tilted headlamps.
• Rib designs includes.
• thickness, quantity, height , manufacturibility and location.

1. The offset surfaces are then trimmed to attain the class B surface.
2. You can even directly offset the class A for obtaining the class B surface.
3. The final class B surface must have the edge fillets similar to the class A and fillets must be given properly with a thought of maintaining same thickness throughout avoiding the flow line defects.

#DOG HOUSE

• Dog house is the attachment feature which helps you to assemble things at certain heights and also resolve the plastic defects.
• There are plenty dog house design which can be used for assembly purpose but we will be using the one provided to ous by the resources.
• The master section or the enginnering drawing must be followed for creating the dog house

PUSH PINS

• These pins are used for the assembly purpose .
• These pins are guided into the sheet metal body.
• The pin is assembled over the dog house on one side and other into sheet metal.

#FLANGES ON THE COMPONENT

• These flanges will be build on the components for the fittment purpose with lower substrate.
• The hole at center will be guided along the heat stakes.
• Later top portion of the heat stake will be melted over it.
• The flange should rest on the supporting ribs on side .