Challenge

Week 11 - Project - A pillar Design with Master Section

PPunnam Nithin8 Aug 2023

AIM : To

Create proper tooling direction following the master section to create the part that meet the requirements
perform Draft analysis check to make sure that the class A surface is meeting the draft required along the tooling direction
Create class B surface and class C surface by following a proper model model tree structure
Create Dog house which meets the draft analysis along the side core axis for dog house

INPUTS

Creation of proper tooling direction following the mastersection to create the part that meet the requirements

Create two lines using point-point method on the mastersections provided for creation of Doghouse as shown

Now create a Line using Line type as Bisecting and select two lines created above and any point on th mastersection as shown

Creation of Side Core Axis

Create an extract on middle surface of dog House as shown and create a point on that surface as shown

Now create the Line using Normal to surface

Draft Analysis Report

No parts can be ejected from the tool if it is having a straight 90 degree profile from its base surface. A small draft angle is provided to each and every area of the component in order to get an easy removal of the component from the tool. Draft analysis technique is used to analyze whether our part model created in cad is manufacturable based on the draft condition applied. Here the part should get easily removed from the panel dies (in case of Sheet metal part) or Mold (in case of plastic). Here we are providing a direction in which components should eject inorder to get an easy removal of components from the tool. In other words it also lets us know whether the model is having a draft angle and how much is the draft angle from the tool direction.

Draft analysis is performed on the components where the ejection of materials happens after the material is made inside the tools. In case of Automotive Sheet Metal manufacturing, the blank sheet after turning into automotive panels like Hood, Fender, Roof, Side Doors, Back Doors etc, need to be removed from Panel Dies. If a considerable amount of draft angle is not provided, the removal components from the tool will be difficult. Same in the case of mold(plastic component) after getting filled inside the core and cavity, it needs to get ejected easily with the help of ejectors.

The major consideration of Draft Analysis is whether sufficient Draft Angle is provided on the component or not . Components while designing should be provided with a considerable amount of draft angle depending on the manufacturing consideration. For Plastic components we provide a draft angle of 3degree(Draft angle of 0.5 is given ideally to the features inside the plastic part). But for Automotive Sheet Metal Parts, it will be from 7 degrees or more.

Procedure to Perform Draft Analysis

i) First,ensure that to Change the view mode to Customize View Parameters and select " Material " option from the Mesh.

ii)Now Go to Insert --------> Analysis----- >Feature Draft Analysis

Draft Analysis dialog box with colour scale (with quick analysis mode) appears on the screen. So the first mode option is the quick analysis mode and second is full analysis mode.

Here the quick analysis mode is used.

iii)Now,click on the component first by selecting the compass icon from the direction of the Draft Analysis dialog box. Compass may get misplaced from its original position after clicking on the compass icon. So Select the compass again place it over Tooling Axis one more time .

iv)Now Activate the compass and place the compass again on Tooling Axis and then click on the component .

v)Now the appearance of the part changes

To get a clear picture, either we need to adjust the compass by holding the marked region of compass and dragging it towards the opposite direction or by selecting the " inverses draft direction option " inside the direction of Draft Analysis

vi)After getting green colour on the component, try to adjust the compass using the knob, and adjust the direction of the compass to get green on the entire top panel region.

vii)Now Try zoom in and check if each and every region of the panel is showing green, if in some region, red or blue is showing instead of green, those negative regions are below 7 degree and have no draft applied on those regions. Those blue and red negative regions need to be changed.

viii) If we are ok with the result, right click on the compass and lock its current position using lock current orientation.

Class A surface

Final Solid Body Without features

Creation of Class B surface

Offset the given class A surface by 0.25mm downwards

To close the patch , use Sweep command Using Profile and the Guide curve as shown

Final Modified Class B surface is obtained by Extrapolation and Sweep command Using Profile and the Guide curve wherever extrapolation doesnt works

Creation of Class C surface

Join Class A surface and class C surface
Trim the join of (A+C) surface and the modified class B surface . The Final component obtained is

Use Close Surface command to convert surface component to solid part

Dog House Construction

Extract the three points on the mastersection provided as shown and Isolate them and convert those points from Explicit to Coordinates by double clicking each points individually one by one
create a Plane using Three points as shown

create a sketch as shown

Now use Project 3D elements for creation of Dog house profile as shown and Isolate them

Now using TRIM command extend the two vertical lines that you projected ,to next points on mastersection as shown

Now measure the mastersection lengths to know the Extrusion limits for creation of Dog House surface as shown

Extrude the profile as shown

Close the backside portion using Multisection surface as shown and Join them together

Insert the body and Thicken the surface to 2.5mm

Create a sketch on top surface of dog house as shown
Now use POCKET

To create Cutout at downside

offset the class B surface on which doghouse is created by 3 to 6mm . Then offset the extruded surface created for doghouse creation to 1.25mm and then Trim as shown