Week 11 - Project - A pillar Design with Master Section
Week 11 - Project - A pillar Design with Master Section
Aim :
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 the 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 close all three surfaces.
- Design the Dog house and its internal parts as given Drafts and mater section sketch.
- Draft analysis for the final solid part and side 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.
Step followed for creation of tooling axis :
- Reference point is first created on extracted surface.
- New axis system is deployed to plot clearance lines.
- The X-direction and Y-direction along the class-A were used to create tooling axis.
- Graphic properties of tooling axis were change before publishing.
Draft Analysis :
The Draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees. A functional part for injection molding has to have Drafts facing both cavity and core sides to reduce the risk of damage to the parts and ensure ejection. And also important is to overcome the vaccume forces by letting air in between the metal to the plastic for the part to relaese properly. Adding maintaining a decent cosmetic finish.
Draft should be a part of design for manufacturing and plastic product Designer should be aware of its need at the outset of the design process. This allows considerations for design requirement to be taken into account.
Nominal values for Draft angle :
- 3 Degrees is the nominal Draft angle.
- 7 Degrees for textured surface.
- At the minimum of 0.5 Degrees can be manufactured by special tools. But it will increase the manufacturing cost.
Tooling Axis Creation :
For this part tooling axis creation is done by using the mater section which is given along the Class A surface. Because in this master section the Dog house is there and the Draft for the wall of the Dog is given by the tooling axis. So can take tooling axis from the master section. This master section and Class A surface is given below.
Class A surface given :
And next step is to sketch in the master section plane by using the bisecting line as shown in figure.
Draft analysis :
- The part created has to be changed to material mode in display frame.
- Compass is enabled and align it along with the tooling direction.
- Lock command is then classified and Draft angle is applied.
- Color codes are classified and Draft angle is applied.
- Running point analysis is used to display permissible draft angle.
Draft analysis for Class-A surface :
- A surface some areas in minimum of draft angle of 2.66 Degree so we need to correct it Class A surface itself by informing to the Class-A surface creating team.
A Pillar closure surface with different views :
- A closure surface is drawn in catia V4
A Solid CatPart of A Pillar in Catia V5 :
Draft Analysis of Solid Catpart in Catia V5 :
- Draft angle is maximum is 1.49 degrees for proper tooling direction.
Side Core Tooling Axis Line :
Master section ;
Dog House side core Draft analysis :
- Draft angle of doghouse is maximum of 0.48 degrees for proper surface finish and tooling direction.
Tree structure :
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 itself by informing to the Class-A surface creating team.