Week 11 - Project - A pillar Design with Master Section

 REPORT:

Aim:

• To Create A-Pillar With Mastersection.
• To Create Tooling Axis,Plastic Component & Solid model With Mastersection.
• To Create DogHouse using Mastersection.
• To perform draft analysis on Class-A surface,Plastic Component,Solid model,DogHouse & A-Pillar

Software Used:CATIA V5.

Commands Used:

• Point,Line,Offset,Multiple Extract,Extrapolate,Trim,Edge Fillet,Boundary,Sweep,Spline,Multi-Selection Surface,Join,Intersection,Split,Sketch,Circle,Draft,Draft Analysis,Union Trim.

Procedure:

Class-A Surface:

• This is the given class-A surface of A-pillar with mastersection.

Tooling Axis:

• The tooling axis is created using the bisecting method.

Class-B Surface:

• To Create class-B surface,directly offset the class-A surface upto distance of 2.5mm.
• Due to direct offset of the class-A surface one of the patch is missing on the offset surface.

• The missing patch is created using sweep with profile type explicit and subtype with reference surface.

Class-C Surface:

• A boundary is created using class-A surface.
• And then using the boundary a sweep is created with profile type as line and subtype with the draft direction in 87°.

Join Class-A & Class-C Surface:

• Join class-A &class-C surface using Join command.

Final Plastic Component:

• Unhide the Class-A&C join surface and the class-B surface.
• Now trim the unwanted surfaces to create plastic component.

Close Surface:

• Using close surface,a solid model of the Door Trim is created from the plastic component.

Doghouse:

• Using 3D projection command,the mastersection is projected and adjusted accordingly to create the sketch of the doghouse.

• Extrude the given sketch using extrude command.

• Then extracted the line,extrude the extracted line and offset the line to the required distance.

• Now trim the unwanted surfaces to form the doghouse surface.

• Now thicken the surface thicken command & Split the surface surface.

• Create the core part and split it.
• Draft the surfaces of the doghouse(Inner:0.5° & Outer:1.5°).

• This is the sketch of the surface cut on the top of the doghouse.

• Extrude the sketch of the surface cut to split it from the top surface of the doghouse.

Creation of ribs in doghouse:

• Using 3D projection command,the mastersection is projected and adjusted accordingly to create the sketch of the ribs in the doghouse.
• Then extruded the sketch and thickened the extruded surface.
• Now draft the ribs surfaces of angle 0.5°.

• Now perform union trim on the to form a doghouse with ribs.

• Now add the doghouse part body to the solid component.

Rib Creation:

• This is the sketch of the rib.
• Extrude the sketch and split it with the class-B surface.

• Draft is provided on the surface of the rib of angle 0.5°.

• Now use add boolean operation to add the to the solid commponent of A-pillar with doghouse & translate it using point-point translation.

Isometric View:

Multi-View:

 Draft Analysis:

 

• Draft Analysis is performed on class-A surface with main tooling Axis.
• Draft is angle is 3°.
• The draft is positive for class-A surface because the minimum draft angle is 3°.

 

• Draft Analysis is performed on the solid component with main tooling Axis.
• Draft is angle is 3°.
• The minimum draft angle is 3° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is -85.01°.

• The minimum draft angle is at this surface is 1.02°.

• The minimum draft angle is at this surface is 2.02°.

 

• The minimum draft angle is at this surface is -4.02°.

• The minimum draft angle is at this surface is -12.5°.

• The minimum draft angle is at this surface is 2.4°.

 

• Draft Analysis is performed on the doghouse with main tooling Axis.
• Draft is angle is 1.45°.
• The minimum draft angle is 1.45° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is -1.064e-007°.

• The minimum draft angle is at this surface is -1.4°.

 

• Draft Analysis is performed on the doghouse with lifter Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is 1.684e-004°.

• The minimum draft angle is at this surface is -88.5°.

 

• Draft Analysis is performed on the ribs in the doghouse with main tooling Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is 0.037°.

• The minimum draft angle is at this surface is -0.034°.

 

• Draft Analysis is performed on the ribs in the doghouse with Lifter Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is -2.332e-006°.

• The minimum draft angle is at this surface is -90°.

 

• Draft Analysis is performed on the doghouse with ribs with main tooling Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

 

• Draft Analysis is performed on the doghouse with ribs with Lifter Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.

• The minimum draft angle is at this surface is -0.7°.

 

• Draft Analysis is performed on the solid component with doghouse using main tooling Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

 

• Draft Analysis is performed on the solid component  with doghouse using Lifter Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

 

• Draft Analysis is performed on the A-pillar with main tooling Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

 

• Draft Analysis is performed on the A-pillar with Lifter Axis.
• Draft is angle is 0.45°.
• The minimum draft angle is 0.45° for all the surfaces except the surfaces in red & biue colour.
• The minimum draft angles at red & blue surface are mentioned above.

Tree Structure:

   

  

   

   

Conclusion:

• Tooling Axis is created with mastersection.
• Plastic component is created with mastersection.
• A-Pillar is created is created with mastersection.
• Solid model of A-pillar is created and Draft Analysis is performed on the Class-A surface,Plastic component,solid component,Doghouse,Ribs & A-pillar.