Challenge

Week 11 - Project - A pillar Design with Master Section

AArun Nehru13 Dec 2023

CATIA DESIGN

REPORT ON A-PILLAR DESIGN WITH MASTER SECTION (DOG HOUSE CREATION) USING DRAFT ANALYSIS METHOD

AIM : Create the Dog House for the A PILLAR DESIGN WITH MASTER SECTION considering the design rules mentioned in the video. Consider the thickness of the part to be 2.5 mm Thick and using Draft analysis Method.

"C" is where the doghouse contacts the backside of the surface.
Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).
The height of ( B ) should be between 3.0 – 6.0 mm.

CLASS A SURFACE : Class A surface is the aesthetic skin data for the automotive part designing and curvature surface to represent the main component.Befor proceed with A surface to analys the Draft angle, if get any mis-match surface reconstruct the A surface.

All visible external surfaces (such as bumpers, grilles, lights, and body panels) and all visible surfaces of see-touch-and-feel interior components (such as dashboards, seats, and door pads) are produced as Class A Surfaces in automobile design software. This can also apply to carpets, mud flaps, trunk panels, and cosmetic covers in the engine compartment. This surface is 0 millimeters thick.

STEP 1 : Verify the Class A Surface's connection. Using the Boundary command, confirm that there is no space between the components.We have two options for checking it: visually or by using the border command.One outside and two inner circular limits make up its three borders.The first check was finished because if there is a green border in between, it appears that the surface has a gap.

TOOLING AXIS : also known as tooling direction, is the primary factor to take into account when considering plastic and mold parts because it determines how the mold part moves and the likelihood that the plastic component will emerge from the mold part (Core and Cavity). Tooling Direction is the direction in which the mold is opened in a molding machine configuration. The tooling orientation essentially determines which way the mold pulls apart. The mold is constructed from two distinct halves: the core and the cavity. Primary direction is another name for tooling direction.

I've made a tooling axis here. I start by removing a foundation surface and building a mid point on it. Subsequently, I draw a line perpendicular to the base surface across this point. I then completed the draft.

STEP 2 : By using Extract Command take the MASTER SECTION LINE as an Extract From Class A surface. For Creating an Tooling Axis. The tooling axis is the direction in which the mold, core, or cavity opens.Using point command make a Center point on Base Surface With Reference Of Master Section Line.From the Center Point Take An BISECTING LINE .and Create an TOOLING Axis With Referal Line of Master section.

SIDE CORE TOOLING AXIS : The direction in which the mold or core and cavity opens is the tooling axis. Connectivity of Class-A surface: Checking the connectivity of the surface, this can be done by creating boundaries or by simply using the join option such that any openings can be easily visualized.and it is created by reference of main tooling axis in an Horizontal Direction.as shown in a below screen shots.

CLASS A SURFACE DRAFT ANALYSIS : To find out if the part you drafted will be easy to remove, use the Draft Analysis command. When doing this type of analysis, color-coded zones on the investigated element are used, which correlate to certain values if there is a departure from the draft direction at any point.
Draft analysis is done to determine whether the minimal draft of three degrees is being maintained after selecting the tooling axis.
The user may quickly determine the right draft angle of a component by using the Draft Analysis. A draft angle is the degree of taper for cast or molded components that runs perpendicular to the parting line. Draft analysis is appropriate for 3D part models.
While testing an draft analysis please ensure whethere it is in a Material Model or not.shown in below screen shots

STEP 3 : Draft analysis is required to check if a part has required draft or not. Draft is required so that a part can be ejected from its mould easily.Draft will be Maximum 3 Degree.But For me its passing at 2.9 Deg So i used to make it as 3 Deg As Maximum Level in Class A surface Draft Analysis Method and it is passing at 3 Deg.Make Sure you are in MATERIAL MODE To Check Draft Analysis.Use Compass in Tooling AXIS while Drafting.

In Draft Analysis If it shows GREEN Colour Surface. its Pass in Drafting.Suppose its shows in RED Colour Surface its Fails in Draft Analysis.its your choice of making Colour code for your convenient.

CLASS B SURFACE CREATION : Class B is a reference surface that the design engineer creates and which is a replica of class A at a distance equal to the part's thickness.

STEP 4 : Offset Class A Whole Surface for Creating an Class B Surface. Because of Complicated part can Be Fully Offset to Creat Class b surface From Class A.

Its Creating Some PATCHES so we are going to work on it.

STEP 5 : For solving this patches use MULTIPLE EXTRACT Command an take an EDGE line as EXTRACTED area and use SWEEP command (with reference surface) To fill the patches and finally use JOIN Command to Join OFFSET.1 and SWEEP.1 at an 0.003mm Merging Distance.

STEP 6 : Finally use BOUNDARY COMMAND to check wheather there is a gap in between the surface. if there is an gap In between the surface its shows green colour boundary line.only edges should be in Green Colour line.If you find any green line at the middle or in between the surface its shows you have gap in the surface and redo it. to close the surface or fill the surface without any patches.only edges should be in green colour.

CLASS C SURFACE : Class C also known as the side wall of the surface, is a reference surface that the design engineer creates to connect Class A and Class B surfaces.

STEP 7 : The boundary was developed by taking class A into account.To build a Class C surface, the sweep command was used for 3 DEGREE, and as a point of reference Line, the primary tooling axis and tooling direction were taken into account. Sweep Command is used to Extend the Border of Class A surface to Vertical direction for Creating Class C surface.

1.Boundary: pick the boundary for the next operation.

2.Swept: swept the selected boundary.

3.Extrapolate: surface can't join properly, so I used to extrapolate those surfaces.

4.Trim: trim those extrapolate surfaces and get a required surface.

5.Join: now join those two surfaces with each other and form a single surface.

The "CATIA Curve Smooth" command is a feature in CATIA, a design and modeling software, typically used for the manipulation of surfaces or curves. This command is employed to smooth out curves or surfaces to enhance their appearance or achieve a more aesthetic shape.

To fill the small patches created in the C surface because in Some Curvy Surface area SWEEP cant be Created.because its shows ERROR. So we can use MULTI-SECTIONS SURFACE Command to fill the PATCHED area as shown in given Below ScreenShots.
after completing the patch work join the MULTI-SECTION surface.1 with SWEEP.5 using JOIN Command.

STEP 8 : Finally join the Class A & C Surface using JOIN Command as told in above STEP 7 (5th POINT). To form an Single surface as Class A & C.

STEP 9 : Finally we are going to connect Class A & C Surface with Class B Surface. You see in some areas the Class A & C surface are Not Inter connected with Class B surface.

For that we are going to use Boundary Command and Extrapolate options to Extend the Required Surface to be Inter Connected with Class A & C Surface with Class B Surface.as Shown in given Below Screen shots.

Required Length of 6mm as been taken for my Surface to Extend and Inter Connect the Class A & C Surface with Class B Surface.as shown in below Screen Shots.

STEP 10 : And use Final Trim for Trimming Class A and C Surface With Class B surface. Finally Surface as been created at 2.5mm gap between Class A and Class B Surface.to form an closed surface with hollow of 2.5mm gap.

STEP 11 : Check Finally There is No any Boundary in the A PILLAR DESIGN surface By using BOUNDARY COMMAND.if there is no any boundarys it shows Error and your work is clear and perfect. if you find any Boundary line its seems you done ah mistake or wrong surface while joining.so read do it.

STEP 12 : And Finally Created Close Surface in PartBody By Using CLOSE SURFACE METHOD.Using TRIM.2

Creation of Engineering features :

DOG HOUSE DESIGN : Doghouse is an engineering element used in the creation of plastic trim. Dog kennels are a supporting element. To increase their strength, other engineering features like snaps, locators, etc.

STEP 13 : After Creating a Closed Solid Surface.To Creat a DOG HOUSE. EXTRACT the Master Section Line and Create a POINT on it wherever you want to creat Dog House and PLANE.after creating point and plane

Creat an SKETCH by Referal of Master Section and it should be ISO Constrained.
and PAD it for Length of (20.258mm) and other side (9.246mm).
Draft it for 1.5mm Deg outer surface using DRAFT Definition Command
After Drafting use SHELL Command to remove the inner object for 2mm thickness in Both sides of Dog house design as shown in below Screen Shots.

STEP 14 : Draft inner surface of 0.5mm by using DRAFT Definition Command.

after drafting. In Outer edge make an FILLET of 2.5mm and Inner edge of 1.35mm by Using Fillet Command.

STEP 15 : Use UNION TRIM for unwanted faces to be removed in Dog House surface to form an single component.

finally Dog House with RIBS are created.

STEP 16 : for creating a Dog House TOP CUTOUT Creat a POINT on Dog House TOP Surface at the Center area and place a PLANE on it as shown in below screen shots.

Creat a SKETCH and draw a DOG HOUSE TOP CUTOUT Radius of 5mm.
and Creat a line at the bottom edge of dog house for 14mm at center area. Check whether it as been ISO Constrained.
PAD it for 3mm using MiRROR option in PAD Command.

After PAD use REMOVE Command to remove the PADED Surface as shown in below Screen Shots.

STEP 17 : Use DRAFT For TOP CUTOUT Surface area of 1.5mm Deg Drafting.and Finally Dog House as been Created Perfectly by Referance of MASTER SECTION.

STEP 18 : After Creating Dog house DRAFT ANALYSIS METHOD is used for Dog house.Draft analysis is required to check if a part has required draft or not. Draft is required so that a part can be ejected from its mould easily.Draft will be maximum 1.45 degree,minimum of 0.45 degree.For dog house Creation.For outer Draft analysis use Vertical tooling axis for maximum of 1.45 degree.and Inner draft analysis use Horizontal SIDECORE tooling axis for maximum of 0.45 degree.Make Sure you are in MATERIAL MODE To Check Draft Analysis.Use Compass in Tooling AXIS while Drafting.

In Draft Analysis If it shows Green Colour Surface its Pass in Drafting.Suppose its shows in Red Colour Surface its Fails in Draft Analysis.its your CHOICE which colour you want as pass or fail its depend upon you and your convenient.

STEP 19 : Use UNION TRIM for removing unwanted or extra part from Dog house and to make an Single Component as A PILLAR DESIGN .as shown in Below Screenshots.

STEP 20 : After completing Union Trim and Finally Use DRAFT ANALYSIS METHOD for whole Component.shown in given Below Screenshots.

After Creating CLOSE SURFACE DRAFT ANALYSIS METHOD is used for Class A surface and Closed Surface.Draft analysis is required to check if a part has required draft or not. Draft is required so that a part can be ejected from its mould easily.Draft will be Maximum 3 Degree.But For me its failing at 2.5 Deg So i used to make it as 2.9 Deg As Maximum Level in Closed Surface Draft Analysis Method and it is passing at 2.9 Deg.Make Sure you are in MATERIAL MODE To Check Draft Analysis.Use Compass in Tooling AXIS while Drafting.

In Draft Analysis If it shows Green Colour Surface its Pass in Drafting.Suppose its shows in Red Colour Surface its Fails in Draft Analysis.its your CHOICE which colour you want as pass or fail its depend upon you and your convenient.

STEP 21 : After Creating Dog house DRAFT ANALYSIS METHOD is used for Dog house.Draft analysis is required to check if a part has required draft or not. Draft is required so that a part can be ejected from its mould easily.Draft will be maximum 1.45 degree,minimum of 0.45 degree.For dog house Creation.For outer Draft analysis use Vertical tooling axis.and Inner draft analysis use Horizontal SIDECORE tooling axis.Make Sure you are in MATERIAL MODE To Check Draft Analysis.Use Compass in Tooling AXIS while Drafting.

In Draft Analysis If it shows Green Colour Surface its Pass in Drafting.Suppose its shows in Red Colour Surface its Fails in Draft Analysis.its your CHOICE which colour you want as pass or fail its depend upon you and your convenient.