Week 11 - Project - A pillar Design with Master Section

REPORT ON A PILLAR DESIGN

THE STEPS TAKEN TO DESIGN A PILLAR ARE AS FOLLOWS

1.INPUTS-

• HERE THE CLASS A SURFACE AND MASTER SECTIONS ARE PROVIDED WHICH IS AS SHOWN IN BELOW IMAGES.
• FROM THE MASTER SECTIONS AS PER THE REQUIREMENT THE DOG HOUSE HAS TO BE CREATED AND THE POINTS WHICH ARE CREATED FROM THE MASTER SECTIONS NEED TO BE ISOLATED AND THERE SHOULD NOT BE ANY REFRENCE/RELATION WITH THE MASTER SECTIONS.

2.TOOLING AXIS CREATION-

• WHENEVER THE MASTER SECTION ARE PROVIDED THE TOOLING AXIS ARE CREATED BY TAKING THE REFRENCE FROM THE MASTER SECTIONS.
• HERE INITIALLY THE PLANE IS CREATED WITH THREE POINTS WHICH ARE ISOLATED.
• CREATE A POINTS ON THE VERTICES OF THE MASTER SECTION THEN ISOLATE THE POINTS, THEN CREATE THE LINE USING TWO POINTS AS SHOWN IN BELOW IMAGES.

• THE 2 LINES THEN BISECTED TO OBTAIN THE LINE AS SHOWN IN BELOW IMAGES.

• THE LINE OBTAINED THROUGH BISECTING IS THEN USED TO CHECK THE DRAFT ANALYSIS, AFTER CLEARING IT IS CALLED AS TOOLING AXIS.

3.DRAFT ANALYSIS ON A CLASS A SURFACE-

• HERE DRAFT ANALYSIS IS DONE TO CHECK WHEATHER THE SURFACES CLEARS OR NOT ALONG THE CORE AND CAVITY SIDE.
• WE HAVE TO SELECT THE DRAFT ANALYSIS TOOL THEN CLICK ON COMPASS, PLACE IT OVER A BISECTED LINE AND LOCK IT. THEN SELECT ON CLASS A SURFACE AND THE RESULTS ARE OBTAINED IN THE FORM OF COLOUR CODES AND ALL THE SURFACES ARE CLEARING THE DRAFT ANALYSIS, HENCE THE LINE IS TERMED AS TOOLING AXIS AS SHOWN IN BELOW IMAGES.
• SOME OF THE SURFACES HAS A MINIMUM DRAFT ANGLE OF 2.4 DEGREES AND IT CAN BE INCREASED IN CLASS A SURFACE IN ALIAS SOFTWARE AS WE CANNOT MODIFY.

4.CLASS B SURFACE CREATION-

• HERE THE CLASS A SURFACE NEED TO BE OFFSET TO OBTAIN THE CLASS B SURFACES WHERE THE ENGINEERING FEATURES ARE MOUNTED.
• AFTER OFFSETING SOME OF THE SURFACES WILL BE MISSING SO WORKING ON THESE ISSUES THE CLASS B SURFACES WILL BE OBTAINED WHICH IS AS SHOWN IN BELOW IMAGES.

5.CLASS C SURFACE CREATION-

• THE CLASS C SURFACE IS FORMED BY CREATING A BOUNDARY ON THE CLASS A SURFACES, USING SWEEP COMMAND THE DRAFT ANGLE OF 3 DEGREE IS PROVIDED WHERE THE SURFACES ARE PARALLEL TO THE TOOLING AXIS AND 90 DEGREE DRAFT IS PROVIDED WHERE TH SURFACES IS PERPENDICULAR TO THE TOOLING AXIS.
• ALL THESE SEPERATE SURFACES ARE TRIMMED TO FORM A SINGLE SURFACES AS SHOWN IN BELOW IMAGES.

6.CLASS A AND CLASS C JOIN-

• HERE THE CLASS C AND CLASS A SURFACE IS JOINED AS SHOWN IN BELOW IMAGES.

7.FINAL TRIM-

• THE JOINED CLASS A AND CLASS C SURFACES ARE TRIMMED WITH CLASS B SURFACE TO OBTAIN A CLOSED SURFACES WITHOUT BOUNDARY AS SHOWN IN BELOW IMAGES.

8.CONVERTING CLOSED SURFACE INTO SOLID-

• TO CONVERT THE CLOSED SURFACE INTO A SOLID MODEL WE HAVE TO DEFINE IN PART BODY OF PART WORKBENCH.
• USING THE CLOSE SURFACE TOOL THE CLOSED SURFACE GETS CONVERTED INTO SOLID COMPONENT AS SHOWN IN BELOW IMAGES.

9.DOG HOUSE CREATION-

• THE MAIN PURPOSE OF THE DOG HOUSE IS TO INCREASE THE STRENGTH OF OTHER ENGINEERING FEATURES LIKE LOCATORS, SCREW BOSS AND HEAT STAKES. IT ALSO HELPS TO REDUCE THE SINK MARKS WHEN INTRODUCED TO INCREASE THE HEIGHT OF ENGINEERING FEATURES.
• HERE THE PLANE IS CREATED ALONG THE MASTER SECTION USING THE THREE POINTS WHICH IS ISOLATED AS SHOWN IN BELOW IMAGES.

• THE SKETCH IS CREATED BY PROJECTING THE LINE, IN WHICH THE POINT IS CREATED AT THE MIDDLE AND THE POINT IS ISOLATED.
• THE PLANE IS THEN CREATED AT THE CENTER FOR THE CONVENIENCE AS SHOWN IN BELOW IMAGES.

• THE NECESSARY POINTS ARE CREATED ALONG THE MASTER SECTION AND ARE ISOLATED WHICH IS AS SHOWN IN BELOW IMAGES.

• ALL THE NECESSARY LINES ARE DRAWN BETWEEN THE POINTS WHICH IS SHOWN IN BELOW IMAGES.

• THE SIDE CORE AXIS IS CREATED WHICH IS NORMAL TO THE PLANE AS SHOWN IN BELOW IMAGES.

• ALL THE LINE ARE THEN EXTRUDED ALONG THE SIDE CORE AXIS AND TRIMMED TO OBTAIN THE SURFACES AS SHOWN IN BELOW IMAGES.

• BY SELECTING A THICKENED TOOL AND PROVIDE A REQUIRED THICKNESS TO THE DOG HOUSE WALL AND RIBS. THE REQUIRED LENGTH OF DOG HOUSE IS SOLID TRIMMED BY TAKING THE LINE FROM THE MASTER SECTION AS SHOWN IN BELOW IMAGES.

• TO CREATE THE WALL THICKNESS (C) AS PER DESIGN RULES OF DOG HOUSE THE SURFACE IS CREATED AND SOLID TRIMMED WITH THE DOG HOUSE AS SHOWN IN BELOW IMAGES.

• TO CREATE A CUTOUT AS PER DOG HOUSE DESIGN THE SKETCH IS DRAWN AND EXTRUDED AS SHOWN IN BELOW IMAGES.

10.A PILLER FINAL COMPONENT-

• HERE ALL THE THICKENED AND PADED PART BODY ARE ADDED TO A PILLER FINAL COMPONENT THROUGH BOOLEAN OPERATION AND NECESSARY DRAFT ANGLE AND RADIUS ARE PROVIDED AS SHOWN IN BELOW IMAGES.

11.DRAFT ANALYSIS ALONG TOOLING AXIS-

• HERE DRAFT ANALYSIS IS DONE SIMILAR TO THE DRAFT ANALYSIS ON CLASS A SURFACES. THE RESULTS ARE OBTAINED IN THE FORM OF COLOUR CODES AS SHOWN IN BELOW IMAGES.

12.DRAFT ANALYSIS ALONG SIDE CORE AXIS-

• HERE THE DRAFT ANALYSIS IS DONE FOR A SIDE CORE AXIS AS SHOWN IN BELOW IMAGES.

13.PUBLICATIONS-

• THE CLASS A, CLASS B, CLASS C SURFACES, SIDE CORE AXIS AND TOOLING AXIS ARE PUBLISHED AS SHOWN IN BELOW IMAGES.

14.EXPANDED TREE STRUCTURE-

• THE EXPANDED TREE STRUCTURE ARE AS SHOWN BELOW.

15.ORIENTATION VIEWS-

• THE ISOMETRIC, FRONT, SIDE AND TOP VIEWS ARE AS SHOWN IN BELOW IMAGES.