Week 11 - Project - A pillar Design with Master Section

 1)

AIM: 

• Create the B-pillar  component through the given Class-A surface. To begin with, the tooling axis for the given Class A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
• Create Dog house using given master section

GIVEN CLASS A SURFACE WITH MASTER SECTION

• Check the connectivity of the Class A Surface
• Ensure that there is no gap between the component, using join command.
• We can visually check it or by clicking boundary command.
• Therefore first check completed.

CREATED TOOLING AXIS USING BISECTION METHOD

• Find the tooling axis of the component.
• The tooling axis is nothing but the mould opens or cavity opens.
• Check visaully which is the best possible tooling axis.
• Check all three axis.
• Now perform the Draft analysis using the Featured Draft Analysis tool in the tools.
• Then after opening the draft analysis tool box go for the compass and place the compass alinged to tooling axis and click on the lock symbol after alinging and further click on the surface.

BISECTING METHOD

• Bisecting method is basically use to find the proper tooling axis using the dummy tooling axis.
• In Bisecting method, bisecting line is used which either bisect the two line or it will show error which means the two lines are parallel to each other.
• In order to know whether the particular surface is toolable or not we intersect the surface with the respective plane and get a sketch which consist of two lines and with the help of bisecting line option we bisect the line which creates a line at the mid point of the two lines.
• Like wise we create tooling clearing axis for x and y which will be used to create the main tooling axis using the bisecting line option in in the line comand.

DRAFT ANALYSIS ON CLASS A SURFACE

• Go to insert< analysis< feature draft analysis.
• Align the tooling axis with the compass.
• Click on the surface and see that the surface is within the permissible limit of the draft values.
• The surface should be green and in the column proper value (3deg) should be inserted.

OFFSETTED AND EXTRAPOLATED B SURFACE

• Offset the class a surface 2.5mm direclty.
• Some patches will form after offsetting.
• Remove the filleted region for closing the patches.
• Define the boundary and extrapolate to required length.
• Now trim the surfaces to required surfaces
• Now provide proper  fillet the surface to required amount

C SURFACE CREATION

• Extract the boundary of the class-A surface. 
• Extract the boundary of the holes on the class-A surface.
• Use sweep command on the boundaries one by one to get the class-C surface.

CREATED C SURFACE

DEVELOPED A and C SURFACE TOGETHER

• Join the class-A and class-C surfaces together
• Trim the class-B surface with the join created earlier.

CLOSED SURFACE

CLOSED SURFACE

DRAFT ANALYSIS ON CLOSED SURFACE

DOG HOUSE INITIAL PROFILE

SOLID SPLITTING USING CREATED SURFACE

SOLID SPLITTING USING CREATED SURFACE

SHELL OPERATION ON THE INITIAL DOG HOUSE PART

SIDE CORE TOOLING AXIS CREATION

OUTER WALL DRAFT ANALYSIS

INNER WALL DRAFT ANALYSIS

 DRAFT ANALYSIS WITH CORING

DOG HOUSE BEFORE FILLETING

DOG HOUSE AFTER FILLETING

DRAFT ANALYSIS AFTER FILLETING

DOG HOUSE WITH KEY HOLE

DRAFT ANALYSIS ON FINAL DOG HOUSE

TRANSLATED AND ROTATED DOG HOUSE

DEVELOPED DOG HOUSE AND B-PILLAR

DEVELOPED DOG HOUSE AND B-PILLAR

FINAL DRAFT ANALYSIS

DESIGN TREE STRUCTURE

EXPANDED DESIGN TREE STRUCTURE

EXPANDED DESIGN TREE STRUCTURE

CONCLUSIONS

• Successfully created  B-Pillar plastic component.
• Successfully performed draft analysis for class a surface and solid close surface. 
• Successfully Developed Dog houses using the master section provided.