Week 11 - Project - A pillar Design with Master Section

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 tooling axis and perform the Draft analysis for the final solid part.

CLASS A SURFACE:

          Class A is an aesthetic surface with the highest quality finish. Most Class A Surfaces for an Automotive Component are made using AUTODESK ALIAS. It is taken as a reference by the Automotive Plastic Designer to create CLASS B, CLASS C surfaces.

TOOLING AXIS AND  SIDE CORE AXIS:

          Tooling axis is the direction in which a core or 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 the draft analysis of the component.

BISECTING METHOD:

• In this way first I 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 B SURFACE:

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

  
  

  C SURFACE:

            C surface is created with help of A-Surface by using the Sweep(with reference surface) and Boundary command separately, finally joined together to get the  final C surface.

  Then join the class A surface to the class C surfaces after that I trim out the joined A and C surface to class B surface to get the final object.
  
  CLOSE SURFACE BODY :-
  
  Now go to Part body feature & make a close body of it. Here the final close body. 
  
  

  DOG HOUSE :- 

  Dog house is an engineering feature used 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.

  • First extract the master-section the following by creating line make sure isolate the line. Then I create a plane through two lines. Then positions the sketch.

  • Projected the master section followed by isolating it. And then came out the sketch. And extrude it. Then by using the command trim and split. I make the side walls.

  • Then go the part body to thicken it by 2.5 mm as measured from the master section.

  • Similarly creating plane and line and then isolating it I created all the required features in dog use.

  • Then gave all the draft like 1.5 degree from the Top & 0.5 degree to the inner core through side core axis.

  • Then finally union trim it with the final part body to create a single final solid body.

    
    

    Procedure for Draft Analysis:-

        i) After creating the Tooling Axix, Class A B C surfaces Go to view mode and ensure that the object is          in customize view parameter mode and also ensure that only material element is checked in                  Shading.

        ii) Now click on compass & drag it to allign it on the main tooling axix & click the lock key to lock the          compass here.

        iii) NOw click on the object to see the draft analysis.

        iv) The colour chart indicates the various conditions of the draft angle. The green colour indicats that           the part passes & can be used for the further operations.

        v) By using analysis under the running point icon we can check the draft angle at the various surface          of the component.