Week 11 - Project - A pillar Design with Master Section

PROJECT-1

TITTLE: A PILLAR DESIGN WITH MASTER SECTION

INTRODUCTION:

The A-pillar is an important load carrying component of any automobile body. It is a primary support structure for the roof and is typically a thin-walled, spot-welded, closed-section structure made from high strength steels. Automobile with major panels welded together is called BODY IN WHITE or BLUE BUCK. This consists of a number of panels; one among them is A-PILLAR. This is a structural member as the sides of the windshield on which doors will be mounted. The paper deals with the modal analysis of an A-pillar, for the given dimensions. The dimensions of the A-pillar are taken from the drawing or references whichever is available. The 3D model is prepared using the CATIAV5 software. Meshing is done in Hypermesh and structural analysis is carried out on A-pillar to determine the natural frequencies and mode shapes of a structure. Post-processing is done using ANSYS software. The A-pillar design’s acceptance is done from the results obtained in analysis on composite reinforced A-pillars. Re-analysis results will show the different results from which best design is selected. It is then fabricated and validated experimentally.

AND WE ARE GOING TO DEVLOPE A-PILLER_INNER CASING USING CATIA WITH GIVEN MASTER SECTION.

MASTER SECTIION

Master sections are the guides for design requirements which decide the component packaging after technical,and other engineering features are all follwed by the given master section,and it is one of the pre analysing stage of product develpoment cyvle.

WE HAVE THE MASTER SECTION THAT IS HAVE ALL THE ENGINEERING FEATURES TO CREATE A-PILLER.

MASTER SECTION REFERENCE FOR CLASS A, CLASS B & CLASS C SURFACE.

        

CLASS A SURFACE

 Check the surface quality 

     

TOOLING AXIS:

The Tooling Direction is basically the direction that the mold pulls apart. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction.

create the two lines with the master section, bisecting the line & create the tooling axis.FOR CLASS-A-SURFACE

        

WHAT IS CLASS-A SRFACE:

In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality. Although, strictly, it is nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, many people interpret class A surfaces to have G2 (or even G3) curvature continuity to one another (see free form surface modelling).

DRAFT ANALAYSIS OF CLASS-A:

        Draft analysis for class A surface

 

 WHAT IS CLASS-B SRFACE:

B' class surfaces can also be referred to as 'engineering surfaces. I have not personally heard of any surface being referred to as a 'C' type. generating visual quality surfaces. continuity. G3 is often sought on the more major block surfaces. G3 deals with curvature "acceleration", i.e. the rate of change of curvature across a boundary.

CLASS B SURFACE

 Create B surface offset form the class A surface as per master section.

       

WHAT IS CLASS-C SRFACE:

• A surface means visible surface.it will give styler.B surface means thickness of a part it is not visible it is inside part. c surface means A and B combined to give C surface

CLASS C SURFACE

 create the surface with swept & multi section surfaces and rework the patches by using multisection surface.

             

FINAL SURFACE(CLOSED SURFACE):

Trim the class-A,B&C surfaces before that join the class a and c surfaces without any boundary,and after triming the surface check surface discontinueity.

 

SIDE CORE AXIS

A slide core is a local core which is normally mounted at right angle to the mould axis for forming a hole or recess in the side face of a molding. This side core prevents the in-line removal of the molding and some means must be provided for withdrawing the side core prior to ejection.

      create side core axis using master section.

DOG HOUSE & RIBS 

  Create the dog house & ribs as per master section.

DOG HOUSE

Create the dog house by using the master section, and extract 3d element tool and the sketches should be fullhy constrined.

Extrude the sketch as per given master section dimensions and then create the solid part body by using the thicken method.

  

To reduce the sink marks we need to provide the small cut out on bottom side of the dog house and consideration of the dimenshions of the dog house we need follow the rules that wall thickness at c should 40 percentage of doghouse wall thickness and cut height should minimum of 6mm from the B surface.

Draft to the dog house along the both side coure axis and main tooling axsi side core axis.

RIBS CREATION :

The creation of ribs as per master section and we follow the all enginnering features consideration while creating the RIBS.

CREATE THE SKETCH:

CREATE THE HORIZONTAL RIBS:

 

CREATE THE SOLID BODY BY USING THICKEN METHOD:

DRAFT THE RIBS ALONG SIDE CORE TOOLING AXIS:

DOG HOUSE TOP PROFILE:

After constrained sketch need to sweep the with minimum draft angle should be maintained as design rules.

Use the split command to get complete part body.

DRAFT ANALYSIS FOR SOLID SURFACE ALONG THE BOTH MAIN TOOLING AXIS AND SIDE CORE TOOLING AXIS:

Draft along the main tooling axis with minumum of 3 degree draft angle 

ALONG SIDE CORE TOOLING AXIS:

  Maintain the minimumm draft angle of as per the master section.

VIEWS:

ISOMETRIC VIEW:

TOP VIEW:

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FRONT VIEW:

TREE STRUCTURE:

CONCLUSION:

In this project we devlpoed automotive plastic part of A-PILLER with all design manafacturing and eng features consideration and we learned how to use Master section as a key,and we maximum we worked on surface and part body work and we learned and femilirized in all tools,at finally we developed yhe A-PILLER.

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