Week 11 - Project - A pillar Design with Master Section

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 a Tooling axis for the given CLASS -A surface.
• Create the CLASS B and C surfaces of door trim using the given CLASS-A surface.
• Create a final surface model and convert it into a solid body using the close surface command in the part design workbench.
• Create side core axis for the dog house
• Create Dog house on the B surface by considering the design rules.
• Perform draft analysis for both Class-A surface and Final part body.

Design Methodology:

Class-A surface means visible surface. It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.

Given CLASS-A surface:

Procedure for Tooling axis creation:

• Check the best possible tooling direction by manually adjusting the compass.
• By analysing it is found that y axis as tooling direction would clear most of the faces without any difficulties.
• Now extract any surface and create a mid-point on it.
• Then create a dummy axis creating a line on the point and direction along the y-axis.
• Perform draft analysis to find whether the given axis clears the draft analysis. If not create a new tooling axis.

Draft analysis of CLASS-A surface:

The blue highlighted Area clearing 2 deg Draft.

CLASS-B surface creation:

Class-B surface means the thickness of a part it is not visible and is inside part. In other words, the Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Create offset surface of CLASS-A about 2.5mm inward direction.
• Check for discontinuity and rework on the offset surface using extract, multi-extract, multi sections surfaces.
• Join the surfaces and ensure the final CLASS-B surface created has no gaps.

CLASS-C surface creation:

The surface that joins class-A and class-B surfare that is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled.

• Create the sweep concerningerence to the surface and tooling axismulti-extractingting the CLASS-A boundary.
• Join the sweep surfaces by using commands like extrapolate, multi-sectiontion surface.
• Finally join all the sweep surfaces and ensure the continuity of the CLASS-C surface.

Creating the Final surface:

• For creating the Finals door trim surface, join the CLASS-A and CLASS-C surfaces together.
• Then Extrapolate the B surfacea little bit outward direction to make sure that there would not be any gap when trimming with the joined surface.
• Then trim the extrapolated CLASS-B surface with the Join surface (CLASS-A and CLASS-C)

DOG HOUSE Creation:

Dog houses are made to prevent the SINK MARK that screw bosses leave on CLASS-A surfaces and to address the length problems that arise when attaching screw bosses to other componentsIt is especially helpful when the part needs screw bosses that are perpendicular to the direction of tooling.

• C thickness should be 40% of the main wall thickness T.
• Minimum width of the dog house is 12 mm.
• Height of B should be 3-6 mm

Draft Analysis for Doghouse:

3D Part model in various orientations (Isometric, Front, Side, and Top View)

Draft analysis of final

The blue highlighted Area clearing 1.5 deg Draft.

Conclusion:-

Created the A Pillar Design with the master section given as the intersection sketch with the Class A surface and created the tooling axis and perform the Draft analysis for the final solid part.