Week 11 - Project - A pillar Design with Master Section

Aim: To Create the A-Pillar Design with the master section given as the intersection sketch with the Class A surface and create the Dog house, tooling axis and perform the Draft analysis for the final solid part.

Objective:

• Check for model
• Tooling axis and Side coring Axis
• Draft analysis for Class-A surface
• Class-B Surface Creation
• Class-C Surface Creation
• Dog House Creation
• Draft analysis for Dog House

Check for model:

Boundary or join command use for check in model any patches.

Tooling Axis:

Tooling axis is the direction in which a core cavity of mold opens. This axis is very important to determine the orientation of the component in mold, core and cavity design as well as to run draft analysis of the component. Tooling Axis is crating of two types first is main tooling axis for main body and the second is side coring axis for dog house for A-Pillar. Tooling axis creation for use bisection method.

Bisecting Method:

• First of all, create the point (between two line) in the extracted master section.

• From the extracted two lines is the key to create the bisecting line and which is going to our tooling axis.
• The same principle was followed to our side core axis creation.

Class-A surface:

• Visible surface and aesthetic look.
• Surface provide by customer (OEM).
• Surface with textures.
• Don't have any features like rib, snap, bosses etc on class A surface.

Class-B surface Creation:

The thickness of the component as 2.5 mm. Now we need to create a B surface which will be similar to the A surface at on offset value of 2.5 mm. There are some discontinuities happed while offsetting the class-A surface so surface so I repaired it to form a boundary by using the multiple extract, extrapolate, trim and fill surface commands and tools.

Class-C Surface Creation:

Class-C surface is created with help of A surface by using the sweep (With reference surface) and Boundary command separately, finally join together to get the final C surface.

Then join the class A surface to the class-C surface after that I trim out joined A surface and c surface to class-B surface to get the final object.

Dog house:

• Dog house is an engineering feature in plastic design. Dog houses are used as support feature. Sometimes other engineering features like snaps, locators, screw bosses are mounted on them to increase their strength.
• Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mould cavity. Dog house and other engineering components are built on the B-surface.
• Dog houses are designed to avoid sink mark created on the class-A surface by screw bosses and to solve the length issues when giving screw bosses which need to be assembled to other components.
• It is also useful when perpendicular screw bosses are required on the part to the tooling direction.
• Make a rectangle to enclose the screw boss in it but make sure it is open from one side sweep it with tooling axis as the pulling direction in wards.
• Close the top face by using multi section surface.
• Thicken it by 2.5 mm.

Daft Analysis:

Conclusion: Class-A, Class-B, Class-C and Dog House creation and draft analysis solve.