Challenge

Week 11 - Project - A pillar Design with Master Section

Aim : The objective of this project is

To create a "A pillar" closed surface from the given class A surface.
To perform a draft analysis on class A surface.
To create a Dog House on the B side surface considering the design rules for that.
To create the Lifter axis for the dog house feature meeting the requirement of the draft angle.
To perform draft analysis on the Dog House Feature.

STEP 1

CLASS A SURFACE

First, open the given class A surface and join all the surfaces using Join Feature. Check the connectivity by using Boundary Feature.
Now, select the Shading with Edges without Smooth Edges option and see whether there is any black lines.
For repairing the dark black lines, use Extract feature and then apply Parallel Curve feature on that extracted lines. And join those parallel curves with drawing lines to close it. After closing it, use join feature on those lines. Now, split those lines form the A surface.
Now, use Multiple Section Surface feature to fill the surface on the class A surface.

Input A surface.

Class a surface after joining with repair work.

Final class A surface.

STEP 2

CREATING TOOLING AXIS

For creating the tooling axis, draw a point on the class A surface and draw a line using that point and the respective direction.

STEP 3

PERFORMING DRAFT ANALYSIS

To perform draft analysis, use Feature draft analysis. For that align the compass to the tooling axis and lock it. Then select the class A surface as the element and click OK to see the analysis.

STEP 4

CLASS B SURFACE

First, offset the class A surface using Offset feature of about 2.5 mm.
After, offseting repair work will be their on the offsetted surface, for that use Multiple Section Surface for filling those surfaces.
Check for any black line on the surface, if so, extract those line then use Prallel curves feature and split those lines form the surface and agian use Multiple Surface Section feature or Blend feature on those gap to fill. Or, we can use fillets of about 0.25 mm to cover those black lines.
Finally, Extrapolate the surface to extand the surface.

Offsetted B surface from class A surface.

Class B surface with repair work.

Final class B surface after extrapolation.

STEP 5

CLASS C SURFACE

Now, create a boundary on the Class A Surface using Boundary feature. And then use Sweep option to the boundary to create a sweep surface with an draft angle of about 3 or 87 degree respectively. If the sweep came properly without any twist and turns or any sharp edges, then its fine. Otherwise we need to sweep seperately from the class A surface using curve smooth feature and sweep and multiple surface section.
After doing that, join all the sweeped surfaces using Join feature.

CLOSED SURFACE

First trim or join the class A surface with the sweeped class C surface.
After that, use trim option to trim the class B surfacre with the joined class A and C surfaces.

STEP 6

B SIDE FEATURE CREATION

DOG HOUSE

First create a axis system on the master section dog house with the help of a point created on line of it.
Each sketch of the dog house is created with positioned sketch with the given dimensional constraints.
The sketches created are extruded and thickned using thick surface option in part design. After doing that, use Add, Remove option from the Boolean toolbar where ever it is necessary.
Finally, use Union trin feature to trim the dog house with the solid component.

Final Dog house feature.

STEP 7

CREATING LIFTER AXIS

First craete a point on the surface on the dog house. After that, draw a line with respect to the point and the respective X-direction which is perpendicular to teh main tooling axis.

Now, perform draft analysis on the dog house by aligning the compass to the lifter axis.

Ship work like this
in your own course.