Week 11 - Project - A pillar Design with Master Section
AIM:
To create a A Piller Plastic Component using a Class 'A' Surface and by using the Closed Surface Feature to create a solid part from the surface and create a B Surface with Attachement feature Dog House Design with supporting Ribs with the master section curves by considering the Thickness of component.
OBJECTIVE:
- To Create a Plastic Component using the Class 'A' surface.
- To create a Tooling axis for a class 'A' Surface, which meeting the requirement of the draft angle and to analyse the solid model.
- To create a solid model from the surface using the Closed Surface Feature.
- To create a Attachement feature Dog House on the created Class B Surface.
- To follow the Master section for thickness and folloe the design rules.
- To create a report which explains the Draft analysis and Tooling Axis cration - colour scale varient.
- To attach the screenshots of the expanded Tree Structure for the Geometrical Sets .
- To attach the screenshots of the 3D Part Model in different orientations.
PUBLICATION:
- Class 'A' Surface.
- Tooling Axis.
- Class 'B' Surface.
- Class 'C' Surface.
- A Piller solid part.
- Lifter Tooling Axis.
INTRODUCTION:
TOOLING DIRECTION:
The Tooling Direction is the direction that the mold pulls apart. The mold is built in two separate pieces,
- A Cavity side and
- A Core side.
The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction. The direction in which the mold or core and cavity opens is the tooling axis.
FEATURES OF TOOL:
- Cavity half – The cavity half is the side of a tool that does not move. It is typically attached to the side of the molding machine.
- Core half – The side of the tool that opens and closes with the mold machine against the cavity half. It opens when removing the part from the tool.
- Cooling lines – Channels that allow coolant to flow throughout the tool and control the cooling of the plastic part.
- Ejector system – Pins on the core half of the tool that helps push the cooled part out after molding.
- Runner – A flow path for the plastic resin allowing the press to inject material directly into the part cavity.
- Side actions – Moving pieces within the part cavity added to allow for undercuts.
A- PILLER DESIGN:
“Pillars” refer to roof pillars, and they’re lettered front to back. A-Pillars straddle the windshield, B-Pillars are in the middle of the passenger compartment (just behind the front doors) and C-Pillars are those at the rear of the passenger compartment.
CATIA 3-D SURFACE TO SOLID PART MODEL - CLOSED SURFACE FEATURE
CLASS 'A' SURFACE:
DESIGN CHECK:
The Class A Surface are Checked Visually by using the Join Feature or by using the boundary feature the Class A surface are selceted and Disassembled the Surface to check the surface are created without the gaps.
The Class A Surface should be created without the boundary Gaps. By using the Join Definition with the Merging distance of 0.001 mm the Class A surface are Joined Together to check the connectivity.
PUBLISHING THE CLASS A SURFACE:
By using the Publication option the Class A Surface are Published. The Publication is used to retrive the Class A surface in the easier way to use from the Structured Tree Implementation.
CREATING TOOLING AXIS:
The Tooling for the Class A Surface are Created in the direction in which the parts are getting Ejected from the Tool. The Tooling Axis which defines the core and cavity pulls apart from the Tooling Direction.
By uisng the Extract feature definition the flat surface are selected and extracted .
By using the Point Definition, The point has been created on the flat surface midpoint.
The Main Tooling Axis has been created using the line definition feature. From the line type point direction, Point has been selected and direction along Y component are selected to define the line.
The Lifter Tooling Axis has been created using the line definition feature. From the line type point direction, Point has been selected and direction along plane are selected to define the line.
MATERIAL MODES:
For the Draft Analysis, the material modes are Selected from the Shading Type.
DRAFT ANAYSIS:
For a Class A Surface, The Draft analysis are to be performed in order to meeting te requirement of the draft angle to the required Tooling Axis. For Plastic component the Minimum angle required for the daft to be 3 degrees.
The Direction compass are to be selected and placed it on the Main Tooling Axis line and the comass are been locked using the lock feature in te direction.
In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,
- For 3 degeree - Green Colour Varient (Positive)
- For 0 degeree - Red colour varient.
- For Negative degeree- Blue colour Varient.
By Using the Running pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the tolling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 42.774 degeree angle.
The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are imled as Blue colour.
CREATION OF CLASS 'B' SURFACE:
With the Master section the Thickness of the part are been measured, by using that the class A Surfaces are been offsetted to the respective distances.
By using the Class A Surface the Class B Surface are created by offsetting to the respective length to the respective direction. By using the offset surface definition the class A Surface are been offsetted to the length of 2.5 mm from the direction towards downward.
By using the Extract definition the surface boundaries are been selected and extrated through which the remaining surfaces are formed.
By using the smooth curve definition the extracted boundaries are been smoothened by the curvatre continuity.
By using the sweep feature the extracted lines are been selected and by the sub type line with references are been selected and profiles are been selected along the guide curve. The faces are been sweeped along the guide curves.
By using the Join feature the sweeped sufaces and the offsetted surfaces are been Joined together with the merging distance of 0.001 mm.
By using the Extrapolate feature the Extracted surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as Point. By selecting the features the boundaries are been extrapolated to the respective length provided. The Class B surface are been created. By using the Boundary definition the Gaps are been identified easily through the crated Class B Surfaces.
CREATING CLASS 'C' SURFACE:
To make the Class C Surface, the Boundaries are been Extracted from the Class A Surface. The outer Boundary, are been extracted using the Bundary feature/ EXtract definitions.
By using the Sweep surface Creation definition, The respective profile type are been selected and subtype with reference surface are been selected. In that the Guide curve are selected as the. Boundary in the Class A Surface, and refrence surface are selected and the Class C Surface are been created.
By using the Sweep surface Creation definition, The respective profile type are been selected and subtype with reference surface are been selected. In that the Guide curve are selected as the. Boundary in the Class A Surface, and refrence surface are selected and the Class C Surface are been created.
By using the Join definition feature the created Class C Surfaces are been Joined together, and also by using the Extrapolation and Trimming feature the edges are been exttapolated and trimmed together to form the class C Surfaces.
The Class C Surfaces are been created by using the sweep feature and also the Direction along the Tooling direction and the reference with the surface and guide curve are been selected to form the Class C Surfaces.
JOINING THE CLASS A AND CLASS C SURFACES:
By using the Join feature the Class A and Class C Surface are Joined Together with the Merging Distance of 0.001 mm.
FINAL TRIMMING:
The Final Trimming Has been performed on the Class B and Joined Class A and C surfaces. The Trimming has been performed.
CLOSED SURFACE:
By using the close surface definition the part surface are selected to make them into solid part from the part workbench.
CREATING B SURFACE ATTACHMENT FEATURES DOG HOUSE DESIGN USING MASTER SECION
CALCULATION FOR THE DOG HOUSE DESIGN:
As per the design rules the Dog House are been created, The Solid part for the Door Trim are been created with the thickness of 2.5 mm. For the Door Trim the Calculation are as follows,
(1). PART WALL THICK (T) = 2.5mm2.5��
(2). Intersection Surface (C) = 0.4⋅2.5mm0.4⋅2.5��=1.00mm=1.00��
(3). Height Of B = 4mm4��
(4). DRAFT = 1.5deg1.5���
By using the Master section the Dog House are been created with creating plane on the Maaster section profile by using the three points. and the center point are been created in between the two points.
By using the positioned sketch the extracted surface are been selected and by using A Positioned Sketch the line has been created is a sketch that has its origin location or orientation defined with construction geometry. As the construction geometry changes the sketch position or orientation will change accordingly.
By using the Extrude feature the created sketchs are been extruded to the respective length to the respective directions.
By using the Trim definition the faces are been selected and by using the Thicken feature Inside thickness are been provided as measured with the master section.
By using the Drfat Definition the faces are been selected to draft for the angle og 0.5 degeree to cut material insides.
By using the split definition the trimmed surfaces are splitted into the Dog House to form the Intersection @ the Class B Surfaces.
By using the Draft definition the faces to draft are been selected and neutral faces are been selected to draft along the pulling direction as side core Axis.
CREATING SUPPORTING RIBS ON DOG HOUSE WITH MASTER SECTION:
CALCULATION FOR THE RIB DESIGN:
As per the design rules the Ribes are been created, The Solid part for the Door Handle are been created with the thickness of 2.5 mm. For the Door Handle the Calculation are as follows,
(1). RIB LENGTH = 5⋅2.5mm5⋅2.5�� =12.5mm=12.5��
(2). RIB THICKNESS = 0.4⋅2.5mm0.4⋅2.5��=1.00mm=1.00��
(3). RIB FILLET RADII = 0.25mm0.25��
(4). RIB DRAFT = 0.5deg0.5���
(5). RIN THICK @ TIP = 0.75mm0.75��
By using the Extracted faces on Top surfaces the surfaces are been offsetted to the respective distances to form the supporting Ribs on the Dog Houses.
By using the Thicken feature the surfaces are been Thickned to the respective distance trough the offsets.
A Draft has been provided on the Created Ribs by using the drfat definition feature @ 0.5 degerees with neutral elements and pulling direction as side core axis.
The Pin Slot are been sketched using the Positioned sketch and Iso constrained using the Geometrical and Dimensional Constraints.
By using the Pad / Pocket features the created 2D sketches are been extruded to the respective directions.
By using te Boolean Operation Remove feature the extruded pin slots are been pocked on the dog House Top faces.By using the Edge fillet definition the edges are been filleted to the respective values.
By using the Boolean Operation feature Union Trim the faces are been selected to remove from the surface and combined together.
DRAFT ANALYSIS:
The Draft Analysis has been performed on the Fianl component created as a closed body using the part design Closed Surface Feature. For Plastic component the Minimum angle required for the daft to be 3 degrees.
The Direction compass are to be selected and placed it on the Main Tooling Axis line and the comass are been locked using the lock feature in te direction.
In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,
- For 3 degeree - Green Colour Varient (Positive)
- For 0 degeree - Blue colour varient.
- For Negative degeree- Red colour Varient.
By Using the pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 88.824 degeree angle.
By using the Side Core Axis the compass are been placed on the Axis to analyze draft on 0.5 deg on Ribs and suporting faces which are clearing on the side core Tooling Axis.
By Using the pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 0.5 degeree angle.
The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are imled as Blue colour.
EXPANDED TREE STRUCTURE:
In CATIA the sketches and te surface operations are been defined using the Geometrical sets. By using the profiles like line, circle, hexagon, polygon, arc the 2 -D sketches are been created with reference to the Geometrical sets. According to the selection of plane from the possitioned sketch the 2-D sketch has drawn with the referene plane.
The surface opeartions like Extrude, extract, trim, split, edge fillets, surface untrim, sweep, smooth curves, extrapolating, Boundary and Fills are deined using te respective geometrical sets.
PUBLICATIONS:
3 DIMENSION PART AND ORIENTATIONS:
ISOMETRIC VIEW, FRONT VIEW, SIDE VIEW AND BOTTOM VIEW:
CONCLUSION:
- The A Piller Plastic Part Component using the Class 'A' surface are Created.
- The Tooling axis for a class 'A' Surface, which meeting the requirement of the draft angle are analysed and perfrmed.
- The solid model from the surface are created by using the Closed Surface Feature.
- To create a Attachement features DOG HOUSE on the created Class B Surface.
- The detailed report which explains the Draft analysis and Tooling Axis cration and colour scale varient are explained.
- As per the Master Sectio the Thickness and the Dog House are been created.
- The Class A, B and C surfaces are Published using the publication option.
- The expanded Tree Structure for the Geometrical Sets are explored .
- The expanded tree structure for part design are explored.
- The 3D part Model with various orientations are attached.