Week 11 - Project - A pillar Design with Master Section

Objective: The main objective of this challenge is to understand the given master section to create a solid body and B-side features for a given class A surface, by considering all the design parameters.

Master Section: Master sections are the guides for design requirements which decide the component packaging after technical (Styling, Concept or Class-A) surfaces.

Overview: Here in this challenge, I created the solid part body from the class A surface and B-side features (Dog house) for the class A surface. The master section measurements are considered to make the solid part body and Dog house. Created a tooling axis by using the bisecting line method and created a side core axis for clearing the B-side feature of the dog house. The draft angle is provided to the dog house outer faces concerning the Tooling axis, and the draft angle to inside faces are provided concerning the side core axis. The draft angle for a solid part body is 3deg, the draft angle for the dog house's outer surface is 1.5deg, and the draft angle for the internal surface of the dog house is 0.5deg.

Tooling Axis creation:

To create the tooling axis, I used the 'bisecting' line method. Initially, I created two lines on the master section by using 'point to point line' and then I created a bisecting line at the centre of those two lines by using bisecting line option in the line command.

Point to-point lines on the master section:

Bisecting line:

Tooling axis:

• 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.
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• Draft analysis for class A surface:

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  The craft analysis check is performed on the class A surface before we create the solid part from that class A surface, to check whether the given class A surface is drafted properly or not. The draft angle for a plastic component is 0.5deg to 3deg).

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• In the above-given images initially, I gave a draft angle of 2.5deg and still some faces are not cleared later I gave a 2deg draft angle to check if all the faces are cleared or not. Still some faces are not cleared with 2deg also, so I reduced the draft angle to 1.9deg, with a 1.9deg draft angle all the faces in class A are cleared properly. 

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• Class B surface creation: 

To create the class B surface initially, I measured the thickness of the master section (2.5mm). I offset the class A surface 2.5mm to the inside direction. The styling fillets on the class A surface are not offset properly, it created the patch on the offset surface. I used the sweep command to close the patch on the offset surface.

Class B surface:

Class C surface creation:

To order to create the class C surface, I used the sweep command. I sweep the class A surface edges along with referencing the surface for 4mm inside with 90deg. After the creation of the class C surface, the surface edges are needed to be extrapolated to intersect properly from all 4 sides. I trim the surfaces which extrapolated, to get the closed class C surface. I joined the class A surface and Class C surface to get a single surface of class A+C surfaces. I trim the Class B surface with class A+C surface join, to get the closed surface to create the solid body.

Class C surface :

class A+C join:

Solid part body creation:

DRAFT ANALYSIS FOR THE CLOSED BODY USING THE MAIN TOOLING AXIS:

Dog House creation:

• To create the dog house on the B-side, I extracted the lines on the master section and I create a plane to extract the lines concerning the master section. 
• I extracted the faces which are required to create the shell for the dog house, and I trim the surfaces with each other as per the master section dimensions. 
• I created the side core access, by creating a line at the centre of the back surface by creating the point.
• I thicken the shell for mm to inside. After thickening the surface, I gave deg draft to inner surfaces of the dog house.
• Now we need to give the bottom cutout for the dog house. To give the bottom cutout, I extracted the surface and offset it to 1mm outside (the bottom cutout should be 40% of the thickness of the dog house). I extract the upper surface of the dog house and offset it to 17mm bottom direction, to trim with the offset of the inner surface.
• After trimming the bottom cutout surface, I split the surface from the solid shell of the dog house. I gave a 0.5deg draft angle to the bottom area concerning to the side core axis.
• I created the rib base and ribs concerning the master section dimensions, and I gave a 0.5deg draft angle to the rib base and ribs. After drafting the rib base, I added the rib base and ribs to the dog house shell to make a single body.
• I created a sketch for the top cutout on the dog house, and I pad the sketch to the downside and removed it from the dog house part body. 

• Using the Master Section we can create a sketch that can be extruded to create the doghouse's walls as shown below

• Dog house:

Draft analysis for the solid part body:

The draft analysis is used to check the surface draft angel and to know whether all the surfaces are drafted properly or not.

• The draft angle for the solid body of A pillar is 3deg, some surfaces are not cleared properly with a 3deg draft angle. Previously I mentioned in the class A draft analysis report with a 1.9deg draft angle all the surfaces are cleared properly.
• The draft angle for the outer surface of the dog house is 1.5deg.
• The draft angle for the inner surface of the dog house is 0.5deg.

Different views:

Isometric view:

Front view:

Right side view: