Week 11 - Project - A pillar Design with Master Section

REPORT : 

• Aim : To create a A-Pillar Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component.

• Objectives : 

  • Creation of Tooling Axis.
  • Creation of Class B and Class C surface.
  • Creating a solid part out of surface modelling.
  • Draft Analysis of Class A surface and final plastic component.

• Introduction : In this project we are designing a A-Pillar using given Class A surface. The approach includes creation of Class B surface keeping 2.5 mm thickness in mind for the complete component. The design also included Class C creation from the given parent surface. 

Constraints :

• NO CHANGES IN CLASS A ARE ALLOWED (BUT CLASS A & CLASS C SURFACE JOIN CREATE OPEN BOUNDARY, SO I HAVE TO EXLAPORATE CLASS A & TRIM WITH CLASS C).
• ALL DESIGN RULES SHOULD BE STRICTLY FOLLOWED.
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID.
• ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS.

CLASS A : Following surface is given as the input for the component creation.

• Creation of Tooling Axis : For the creation of main Tooling Axis I take the master-section as a reference. I extract two lines from the master-section of the Dog House & create a point between those two lines. Then I create a bisecting line with the help of those extracted lines & the point between them. The bisecting line is te main Tooling Axis at Y-axis direction.

• Draft Analysis for Surface A :

  The analysis is done for 3degree draft. So as can be seen all the surfaces are more than 3deg.

• Creation of Class B : 

  • Now for Class B creation, we have extracted surface from Class A and untrimmed them to obtain the original parent surface. 
  • These surfaces are then offset to the required thickness as per the master-section.
  • After offsetting, all the surfaces are trimmed into the required shape.
  • Required fillets are given to the surfaces.

• Creation of Class C surface : 

  • For creating this surface we have extracted the boundry of Class A using multi-extract and then converted to smooth curve. 
  • Now this smooth curve is swept along the draft direction with a 3deg draft.
  • Also some smooth curve is swept with the reference of the A-surface with a 90deg draft.

• Final Product : 

  Class A + Class C :

  To make sure that there is not any open boundry between class A and class C, we have used join option to created the single body. This is done to make sure that the parting line doesn't lie between the these two surfaces.

• Class A + Class B + Class C : 

  For this we have trimmed the above shown surface with the Class B surface using trim feature.

All the main features are published as can be seen in the image shown above.

• Close Surface : We perform a close surface operaration to ensure that there is no open boundary of the final product of the A-Pillar.

• Draft Analysis on the Final Component : For this analysis, main tooling axis is taken draft reference. Following results were obtained.

• DOG HOUSE DESIGN : As per the master-section I extract the lines & project them in sketches. Then I extrude the lines & trim the extruded surfaces as per requirement. Then I do the thicksurface operation with the trimmed surfaces. For rib I do same & untrim it with main Dog House. Then I untrim the Dog House with main body.

• Draft Analysis on the Final Component with Dog House : For this analysis, main tooling axis is taken draft reference. Following results were obtained.

• ISOMETRIC VIEW :

• FRONT VIEW :

• SIDE VIEW :

• TOP VIEW :