Week 11 - Project - A pillar Design with Master Section
AIM :
A PILLER DESIGN MASTER SECTION . ENSURE USING THE SURFACE COMMAND , CLOSED BODY COMMAND TO CREATE THE SOLIDS , THE GEOMETRICAL SET PROPERLY . 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 THR FINAL SOLID PART .
OBJECTIVE :
CREATE THE REQUIRED TOOLING AXIS BY USING MASTER SECTION AND BISECTING METHODE .
DESIGN THE CLASS B AND CLASS C SURFACES AND CLOS ALL THREE SURFACES.
DESIGN THE DOG HOUSE AND ITS INTERNAL PARTS AS GIVEN DRAFTS AND MASTER SECTION SKETCH.
DDRAFT ANALYSIS FOR THE FINAL SOLID PART AND SODE CORE DRAFT ANALYSIS.
THEORY:
TOOLING AXIS :
CLASS -A SURFACE IS FIRST ANALYZED TO CREATE THE TOOLING AXIS OR TOOLING DIRECTION THAT MOLDS PULL APART IN INJECTION MOLDING . TOOLING DIRECTION IS IMPORTANT FOR PLASTIC PRODUCT DESIGN AS IT DECIDES DIRECTION FOR MOLD SEPERATION
ROLE OF THE A -PILLAR :
A-PILLAR IS LOCATED ON EITHER SIDE OF YOUR CAR,S FRONT WINDOW ( OR WINDSHILED ).
THEY ALSO HOLD THE HINGES OF YOUR CAR,S FRONT DOORS . A- PILLARS ARE NORMALLY MADE OF STEEL ALLOYS.
BESIDES BEING A SUPPORTING MEMBER , A- PILLARS ARE VERY CRUCIAL AS FAR AS SAFETY IS CONCERNED . A -PILLARS USUALLY CARRY A SIGNIFICANT AMOUNT OF LOAD DURING A FRONTAL COLLISION OR A ROLLOVER CRASH. SO THE LARGER THE WIDTH OR CROSS -SECTION , THE GREATER WOULD BE THE STRNGTH BUT A-PILLARS ALWAYS BLOCK THE DRIVER ,S VISION ( CREATE BLIND SPOTS) TO SOME EXTENT THAT CAN BE REALIZED WHILE DRIVING . SO HAVING THAT SAID , USING THICKER A-PILLARS CAN MAKE THE SITUATION EVEN WORST. IT MIGHT FURTHER LOWER THE DRIVER ,S VISION AND RAISE A QUESTION ABOUT THE VEHICLE,S AND PASSENGER SAFETY.
HENCE , THE DESIGN OF A- PILLARS MUST BR OPTIMIZED GIVING EQUAL IMPORTANCE TO BOTH STRENGTH AND THE DRIVER,S VISION .
FIRSTLY , WE HAVE TO CREATE THE REQUIED TOOLING -AXIS FOR THE GIVEN CLASS A SURFACE WHILE MEETING THE REUIREMENTS OF THE NECESSARY DRAFT ANGLE & THEN PERFORM THE DRAFT- ANALYSIS OPERATION ON THE CLASS A SURFACE ITSELF.
AFTER THAT WE HAVE TO CREATE THE REQUIRED CLASS B & CLASS C SURFACES USING WHICH WE HAVE TO MAKE THE FINAL PLASTIC COMPONENT AND PERFROM DRAFT ANALYSIS ON IT .
MAIN REPORT :
TYPES OF SURFACES AND THEIR IMPORTANCE FOR AN AUTOMOTIVE PLASTIC DESIGNER:
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 BASED ON THE FINAL CONCEPT -SKETCH . ALL CLASS A SURFACES SHOULD HAVE 'CURVATURE -CONTINUITY' MEANING THE CONTINUITY BETWEEN THE SURFACES SHOULD SHARE THE SAME BOUNDARY. IT IS TAKEN AS A REFERENCE BY THE AUTOMOTIVE PLASTIC DESIGNER TO CREATE CLASS B AND CLASS C SURFACES .
CLASS B SURFACE : THE CLASS B SURFACE RESIDES BELOW THE CLASS A SURFACE AT A CERTAIN THICKNESS. IT IS CREATED USING ENGINEERING PRINCIPLES THAT CONSIST OF ALL THE NECESSARY FEATURES SUCH AS RIBS , BOSSES, SNAPS . ETC. THIS SURFACES ISN'T VISIBLE TO OBSERVER FROM THE OUTSIDE .
CLASS C SURFACE : THE CLASS C SURFACE IS THE SURFACE CREATED BETWEEN THE CLASS A CLASS B SURFACES TO JION THEM WITH EACH OTHER.
NOW , WE WILL BEGIN BY CHECKING THE STATE OF CONNECTIVITY FOR THE CLASS A SURFACE AND ENSURE THAT THERE ARE NO GAPS BETWEEN THE SURFACES SHOULD BE JOINED WELL TOGETHER WITH EACH OTHER AND SHOULD N'T CONSIST OF ANY BETWEEN THEM.
CLASS - A SURFACE :
PROCEDURE TO CREATE THE MANI TOOLING AXIS :
SINCE WE HAVE A MASTER SECTION PROVIDED TO US USING WHICH WE HAVE TO CREATE THE DESIRED A -PILLAR PLASTIC COMPONENT , WE 'II USE THAT SECTION BY EXTRACTING THE LINES AS SHOWN BELOW AND CREATE A BISECTING LINE WITH RESPECT TO THOSE EXTRACTED LINES TO CREATE OUR MAIN .
DRAFT ANALYSIS ON THE CLASS A SURFACE :
NEXT , WE WILL PERFOM A DRAFT ANALYSIS ON THE CLASS A SURFACE ITSELF:
BEFORE STARTING WITH A DRAFT ANALYSIS OPERATION , WE WILL GO TO THE CUSTOMIZE VIEW PARAMETERS, OPTION UNDER THE VIEW TOOLBAR . THEN WE WILL ENTER THE 'CUSTOMIZE VIEW MODE ' WHERE WE WILL GO UNDER THE MESH OPTION AND SELECT MATERIAL AND PRESS OK.
TART THE DRAFT ANALYSIS . ONCE FOUND , WE WILL GO UNDER THAT AND CLICK ON ' FEATURE DRAFT ANALYSIS . THIS WILL OPEN THE 'DRAFT ANALYSIS' DIALOGUE BOX. THERE, WE WILL ENSURE THAT UNDER MODE WE HAVE SELESCTED QUICK ANALYSIS ' UNDER DISPLAY WE WILL SELECT SHOW OR HIDE THE COLOR SCALE AND THEN SELECT 3 DEGREES AS THE PERMISSIBLE DRAFT ANGLE . THEN UNDER DIRECTION WE WILL CHOOSE THE ICON WITH THE SYMBOL OF THE COMPASS ON IT WHICH STANDS FOR USE THE COMPASS TO DEFINE THE NEW CURRENT DRAFT DIRECTION.
IT IS EVIDENT FROM THE ABOVE IMAGE THAT THE DRAFT - ANALYSIS ON OUR CLASS A SURFACE WAS SUCCESSFULL AND THE COMPONENT IS FEASIBLE TO MANUFACTURE .
AT THE REGION SHOWN BELOW THE DRAFT ANGLE IS LOWER THAN 3 DEGREES BUT ONLY BY A SMALL AMOUNT .
WE CAN COMMUNICATE THIS DEVELOPMENT WITH THE CLASS A SURFACE DESIGNER AND REQUEST THEM TO RECREATE THIS REGION SO THAT IT 'II CLEAR PROPERLY WITH THE MAIN TOOLING AXIS BUT FOR NOW WE'RE GOING TO CONTINUE WITH THIS CLASS A SURFACES.
B SURFACE :
C SURFACE CREATING :
A+ C SURFACE TRIM :
FINAL CLOSED SURFACE :
CLOSED BODY IN PART MECHANICAL :
DRAFT ANALYSIS FOR THE CLOSED BODY USING THE MAIN TOOLING AXIS :
PROCEDURE TO CREATE THE ENGINEERING FEATURE - DOG HOSE USING THE MASTER SECTION :
using the master section we can create a sketch taht can be extruded to create the doghouse ,s walls as shown below :
draft face :
in the draft -analysis:
GREE COLOUR STANDS FOR REGINOS WHERE THE DRAFT ANGLE IS MORE THAN 0.5 DEGREES,
BLUE COLOUR STANDS FOR REGIONS WHERE THE DRAFT ANGLE IS BETWEEN 0-0.5DEGREES,&
RED COLOUR STANDS FOR REGIONS WHERE THE DRAFT ANGLE IS LOWER THAN 0 DEGREES
IT IS EVIDENT FROM THE ABOVE IMAGES THAT THE DRAFT ANALYSIS IS SUCCESSFUL AND THE A-PILLAR WITH THE DOG HOUSE IS FEASIBLE TO MANUFACTURE.
FINALLY, USING THE BOOLEAN OPERATION , WE ,RE GOING TO ADD THE DOG HOUSE THE CLOSED .TREE STRUCTURE:
3D VIEW :
CONCLUSION :
HENCE THE A PILLAR DESIGN WITH THE MASTER SECTION GIVEN AS THE INTERSECTION SKETCH WITH THE CLASS A SURFACE IS DONE SUCESSFULLY AND CREATE THE TOOLING AXIS AND PERFORM THE DRAFT ANALYSIS FOR THE FINAL SOLID PART IS ALSO DONE SUCCESSFULLY . FROM THE DRAFT ANALYSIS FOR CLASS A SURFACE SOME AREAS IN MINIMUM OF DRAFT ANGLE OF 2.66 DEGREE SO WE NEED TO CORRECT IT CLASS A SURFACE FINAL CREATING DOG HOUSE .