Week 11 - Project - A pillar Design with Master Section

Aim-

Create the A Pillar Plastic component through the given Class-A surface and master section and perform Draft analysis.

Design -

• Class A surface is given by styling team  and this part gives to design engineer to create part with engioneering features.
• Tooling Axis we need to take specifically and check draft anaylisis and take best tooling axis by adjusting compass.
• Class B surface we need create from Class A surface by offsetting class A surface below a certain thickness . Offset can be done as per requirment . Usually offset value is 2.5 mm inward direction.
• For class B surface creation we need to check discontiunity and work on the offset surface by operations like extract , multi section surface , extrapolate , trim and split etc.
• There should be no any gap in class B surface .
• Class C surface will be created in class A surface by sweep operation which join class A and class B surface.Sweep can done as per requirement like with referance to surface or with referance to tooling axis and sweep angle will be provided .
• For Creating final trim join class A and Class C surface together. and there should be no boundry in this join.Extrapolate class B surface and this class  B surface should intersect with join class A and C. For ensure we should take intersection betwen Join and class B and make sure there should be no any black mark . it means there is still gap or surfaces are not intersecting with each other.
• Now, trim this updated class B surface with  join ( class A and class C).
• verify if there is still any boundry and no boundry should be present . Make this part as solid by closing the surface.

A Piller Master Section- A-Pillars straddle the windshield.

Master Section: Master sections are the guides for design requirements which decide the component packaging after technical (Styling, Concept or Class-A) surfaces. Creating this master section should need 5 to 6 years of experience. This helps you to decide the feasibility, clearance, the packaging and the fixation strategy before working it on a 3D.

Dog House: It is an engineering feature used in plastic trim design. It is used as a supporting feature. By using dog house, we can support the other engineering features like heat stakes, screw boss and locators to locate them at a certain height where we cannot violate the design rules for the features. By using doghouse, we can avoid sink marks in class A surface.

Parameters-

Thickness- 2.5 mm 

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 .

Maximum Draft- 5 degree.

Conclusion-

• Created Tooling axis
• Created Class B and Class C surface from given Class A surface.
• Created solid part out of surface modelling.
• Created solid part out of surface modelling.
• Draft analysis of Class A surface and final part is also done.