Week 11 - Project - A pillar Design with Master Section

A-PILLAR DESIGN WITH MASTER SECTION

OBJECTIVE:

To create the A-Pillar's Plastic component from the given Class A Surface using the Master Section that is provided while following all the design rules.

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. It is taken as a reference by the Automotive Plastic Designer to create CLASS B, CLASS C surfaces.

Given class A surface

TOOLING AXIS:

Tooling axis is the direction in which a core or cavity of mould opens. This Axis is very important to determine the orientation of the component in mould, core and cavity design as well as to run the draft analysis of the component.

Tooling Axis

Side core Axis

B SURFACE:

· Offset the surfaces to 2.5 mm to create the thickness.

· Check whether all the surfaces are properly offset.

· Some edges that are not created clearly, thus the area would be created with a multiple extract and extrapolate options.

· Join all the surfaces together.

· While trimming with the class c surface some of the parts do not coincide, will extrapolate by selecting the outer boundary.

B Surface

C SURFACE:

• Extract the boundary from the class A surface using the boundary command.
• Use sweep command > choose profile type as line > subtype as with draft direction > choose guide curve and draft direction > the minimum draft angle should be 3 degrees.
• After getting sweep extrapolate each corner to get in contact and then trim the output to create single part.
• Then join the swept part with the class A surface.

C Surface

FINAL TRIM:

Then trim the class A and C surface with the class B surface created to get the final closed output.

Final Trimmed surface

Closed surface (Final Trim)

DOG HOUSE:

Dog house is an engineering feature used in plastic design. Dog houses are used as support feature. Sometimes other engineering features like snaps, locators, screw bosses are mounted on them to increase their strength which helps in reducing sink marks due to the excess height

Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mould cavity. Dog house and other engineering components are built on the B-surface.

Dog House Outer Wall Creation

Dog House With Cut-Out Created with Inner Wall with Rib

DRAFT ANALYSIS:

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

A SURFACE Draft Analysis

A SURFACE Draft Analysis Deviation value

CLOSED BODY Draft Analysis

FINAL CLOSED SURFACE Draft Analysis

DOG HOUSE WITH SIDE CORE AXIS

Tree Structure

CONCLUSION

The Tooling Axis and the Solid CAT part with B side feature is created from the given Class A Surface and Draft Analysis is Performed.