Week 11 - Project - A pillar Design with Master Section

AIM: -

• To create a Pillar Design with the master section given as the intersection sketch with the Class A surface.

OBJECTIVE: -

• Create the appropriate Tooling Axis.
• Draft Analysis for Class-A Surface.
• Create the Class-B and Class-C Surfaces.
• Create Side Core Axis
• Design the Dog House and its inside components using the provided draft and a Master Section.
• Draft Analysis for Dog House along Side Core Axis.
• Draft Analysis for the Final Solid part.

GIVEN THE CLASS-A SURFACE

GIVEN THE MASTER SECTION SKETCH

MASTER SECTION 1	MASTER SECTION 2

RULES TO FOLLOW FOR MAKING A DOG HOUSE

• 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

DETAIL TREE STRUCTURE

CREATION OF TOOLING AXIS

We must first determine the best acceptable tooling direction using the compass to establish the tooling axis. Because most surfaces are cleared in the y direction while doing draft analysis, the y direction is appropriate for constructing the tooling axis. Normally, the tooling axis is generated by bisecting a line, however, in this case, a line normal to the surface is created in the y direction and used as the tooling axis.

• Extract the CLASS-A surface.
• Create a point on the extracted surface.
• Now, draw a line using the point direction along the Y-direction, Tooling Axis.

DRAFT ANALYSIS OF CLASS A SURFACE

• We do a draft analysis after creating a tooling axis. Before we begin further, we must ensure that the materials are chosen in the view mode.
• We drag the compass from its current location to the tool axis after selecting the feature draught analysis tool. Then secure the compass. After that, choose anywhere on the component to see the outcome.
• We reduce the component's minimum draught to 3°.
• To examine the angle of the component, we may utilise the running point option.

CREATION OF CLASS-B SURFACE

• The component's thickness is 2.5mm.
• Now we must design a B surface that is comparable to the A surface but has a 2.5mm offset.
• Because some discontinuities occurred when offsetting the CLASS A surface, I restored it to produce a closed boundary utilising the various extract, extrapolate, trim, and fill surface commands and tools.

CREATION OF CLASS-C SURFACE

• To make the Class C surface, we must first unhide the Class A Surface and extract its borders separately on all four sides.
• 'Curve Smooth' will be used to smooth those extracted boundaries.
• Then we'll use the 'Sweep' command with the 'Reference Surface' and 'With Draught Direction' options to construct the Class C Surface.
• By using Join and Trim commands we combine all four sweeps and C Surface is formed.

CREATION OF SOLID BODY

• Join the CLASS-A and CLASS-C surfaces to make the SOLID BODY.
• Then, extrapolate the B surface slightly outward to ensure that there is no gap when trimming with the linked surface.
• The extrapolated CLASS-B surface is then trimmed with the Join surface (CLASS-A and CLASS-C).

CREATION OF DOG HOUSE BY USING THE GIVEN MASTER SECTION

• Extract the horizontal line of the master section.
• Create a point on the extracted line by using the middle point option in the point command.
• Create a line on the point and the line is called SIDE CORE TOOLING AXIS.

• Now, create a plane on the point.
• Draw a sketch by using the created plane and point.

SKETCH OF THE OUTER BODY OF THE DOG HOUSE	SKETCH OF TOP CUTOUT SECTION OF DOG HOUSE
SKETCH OF THE CONNECTOR	SKETCH OF THE RIBS

• Now, extrude the sketch of the outer body of the dog house.

• By using the Multi-Section Surface command fill the surface of the dog house.

• Extrude the sketch of the top cutout section of the dog house and by using the split command cut the top surface.

• Go to the Part Workbench to add a 2.5mm thickness and draft the outer surface with the tooling axis and the inner surface with the side core tooling axis about 0.5deg.

• Follow the same procedure for the connector and ribs.
• Apply the union trim command within the outer body, connector & ribs.
• Now, Extract the inner surface of the dog house and offset by 1 mm.
• Extrapolate the extracted surface and trim it with the offset surface of a solid body.
• Apply split command and remove the bottom portion of the dog house, give fillets to it and Union Trim with the solid body.

DRAFT ANALYSIS OF DOG HOUSE WITH SIDE CORE TOOLING AXIS

DRAFT ANALYSIS OF FINAL SOLID BODY

SCREENSHOT OF THE DIFFERENT ORIENTATIONS OF THE SOLID BODY (ISOMETRIC, SIDE, TOP, FRONT)

FRONT VIEW

RIGHT HAND SIDE VIEW

LEFT HAND SIDE VIEW

TOP VIEW

ISOMETRIC VIEW