Week 11 - Final project
Arm rest :
Creation of class A surface:
Extraction of individual given surfaces , and checking the quality of given surface.
-Final Class A surface
-Tooling Axis
Since there is presence of undercut in the arm rest we have to provide 2 tooling axis for the same.3 degrees of draft has been provided so the smooth functuning of core and cavity block.
Main tooling axis:-
Side tooling axis:
- Draft provided on flanges 0.5 degrees
Class B draft.
Class c Draft:
Due to improper surface of class A not at every point class c surface gets cleared.
->Lower substrate :
DG 1 clearance 0.5 degress draft on inside and 1.5 degress draft on outside walls.
DG 2 clearance:
Heat Stake clearance: 0.5 degres draft
Class A / Class B / Class C draft analysis:
Due to improper surfaces at some areas class C draft is not clearing in all the areas.
->MAp Pocket
Draft analysis of class A /b /c surfaces
Drafting on flanges 0.5 degress.
-> Bottle holder
draft analysis of solid body with flanges.
depending upon the location some of the flanges gets clear using normal to surface tooling axis.
Drafting of class A /b /c sf.
->Complete assembly
Since push pin is getting clashed with the bottle holder , the location of dog house can be shifted little backwards.
->Steps followed for the design.
Step 1: Downloading the step file , and segregating part by part in the product file in catia, following the top bottom approach for design.
Step 2: after segregating checking of class A surface depending upon the given condition , if needed need to cure the design as in arm rest.
Step 3: Creation of tooling axis irrepective if different components.
Step 4:Creation of Class B and C surface irrespective of the classes.
Step 5: Creation of engineering features Dog house, flanges , heat stakes etc.
5-1 Creation of Heat stakes:
Head stakes are created on the lower substrate so that the another component gets fixed rightly on it. Creatio of heat stakes start with measuring the distance between the centre point of the master section upto the edhe that needs to be offseted.
Location of heat stakes: Heat stakes are located at minimum gap of 50 mm form ctc . location varies depending upon he space , since there in no space for tool to go underneath arm rest heat stakes cannoy be created at that location., Draft analysis is carried out on heat stakes at 0.5 degrees in the direction of plane.
Dog houses:
Dog houses is the supporting member incase of the height is too big to create an heatstake.Dog house is created at minimum awalable distace from the open area to be 90mm. depending upon the surfaces , coring needed to provided as per the design rules.Design of coring start from extracting & offsetting the portion underneath the dog house . From the solid part of dog house from the back face is extracted and intersected with the offsetted surface underneath the dog house. we get and clear manufacturable coring curve . Note the lenth of coring varies with 3-6mm inorder to eliminat the sink marks on the surface.
Both the dog house are created in the similar way. The 2nd dog house needs to be shifteed as there is clasing betwwen the push pin and bottle holder.
5-3 creation of flanges:
Flanges are created inorder to connect parts to each other. Flanges are created on the parts that dont have heatstakes as to the heatstakes gointo the flanges and during the melting both the portion gets locked with each other. In the area of MAP pocket an heat stake is created as we have not shown the attachment of flanges.
Kindly note; there is an intersection between the map pocket and bottle holder.
Step 6. assembly,
Push pin in inserted into the component and other that pushpins all the components are fixed on their places , after the components are fixed the master section gets differ.
before assembly the master sections following the parts, after assembly the parts are shifted.
->Parting lines
Arm rest
Lower substrate:
->Map Pocket
->Bottle holder
-Dog house parting line
