Week 11 - Project - A pillar Design with Master Section

A-Pillar Design with Master Section

Aim -

• Create the A Pillar Plastic component through the given Class-A surfac
• Design features according to themaster section and according to the design requirements.
• Perform Draft analysison the class A surface and the final part.

Provided Data -

Introduction -

A-Pillar of a vehicle is located at either sides of the front windshield. They also hold the door hinges and are very crucial for the safety of passengers and for structural support/rigidity of the vehicle body. A-Pillars always blocks a part of the driver’s vision and thus creates blind spots. Thus the thickness of the A-pillar is a very important factor all-together and it’s design must be so that equal importance is given to strength, safety and driver’s vision.

Design of A-pillar -

1. Check the given Class A surface for any discontinuities. Ensure that there are n gaps, if any errors are found repair them and create a good Class A Surface.

2. Create the Main Tooling Axis with the given master sections as reference.

3. Conduct the Draft Analysis of the Class A Surface.
4. Using the given Master Section as reference, create the Class B surface by offsetting the Class A by the required amount.

5. Check for discontinuities on the Class B Surface and repair the errors, if found.
6. Create the Class C surface by using sweep command on the boundaries of the Class A Surface. Extract the boundaries into smaller more manageable boundaries to avoid errors and self-intersections.

7. Join the Class A and Class C surface together.

8. Extrapolate the Class B Surface so that it intersects with the Class A&C joined surface.
9. Trim the Class B surface with the Class A&C Join to form the Hollow Closed Surface.

10. Use the ClosedSurface command in part workbench to create the solid part body for the A-Pillar.

11. Conduct Draft Analysis on this A-pillar Partbody.

Design of Engineering Features -

1. Use the given Master Section to determine the location of the Dog House and other features.
2. Create the Core access Tooling Axis with reference to the Dog House’s walls and the given master section.

3. Create an iso-constrained & positioned Sketch of the profile of the Dog House.

4. Extrapolate the profile with reference to the Master Sections.
   - Trim using surfaces extrapolated from the edges from the master section.

5. Thicken the surfaces and provide required draft to the outside faces with reference to the Main Tooling Axis.
6. Provide edge fillets on the outside and inside of the Dog House.
7. Create a Sink-mark prevention feature on the Dog House, using faces extracted and Offsetted, using the Split command.

8. Design the additional engineering features on the Dog House in a positioned iso constrained sketch (i.e, The Cross Surface in the Dog House , the Ribs positioned on the cross surface and the Screw Boss on the Top surface).

- Add the Cross-Surface to the Dog House.

- Remove the Screw Boss Area from the top surface of the Dog House.

- Add the Ribs to the Dog House.

9. Thicken and add fillets to these surfaces . Also add draft to the faces according to the Side core Tooling Axis.

10. Conduct the Draft analysis of the part with respect to both the Main Tooling Axis and the Side-core Tooling Axis.
11. Union Trim the Engineering feature to the A-pillar partbody to get the final component and provide fillets to the edges.

12. Also perform a Draft analysis of this final Part with the Main Tooling Axis as reference.

Tree Structure -

Draft Analysis -

Class A Surface :

A-Pillar Solid Surface :

Engineering Feature

• With respect to the Main Tooling Axis:

• With respect to the Lifter Tooling Axis :

Final Part :

Final Component Views -

Isometric View :

Side View :

Front View :

Top View :

Result And Conclusion -

• The A-Pillar Plastic component is designed fromthe given Class-A surfac
• Engineering features are Designed according to themaster section and the design requirements.
• A Draft analysisis performed on the class A surface, the Engineering feature and the final part, all passes the inspection.