Week 11 - Project - A pillar Design with Master Section

A PILLER  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 accordingly  and create the tooling axis and perform the Draft analysis for the final solid part.

 

OVERVIEW :

First create a geometrical set with proper sutitable name it as a Surface A. Then we need to do offset into 2.5mm and named it as a ( Surface b ). After that we will get some patch surface in fillet portion due to that fillet in "A" surface. Once we cleared all patches then join them together and name it as "B" surface improved. And then now do the sweep operating in A surface And then trim it and named it as C surface, then join together with A & C surface for final trim. Before going to do final trim make sure wheather the boundary having closed boundary or not then do the final trim with B surface & Joined surface A & C.

Before doing close surface ensure that you have zero boundary surface After that do then closed surface. Then create a main tooling axis using two line bisecting method with point. And also create a side core axis using dog house rear surface.Then finally perform the draft analysis with the draft valve for 3 deg in closed surface and 0.5 deg for dog house side core. 

 

 

 

MASTER SECTION

 

Master section is the main part of a porduct life cycle.It includes feasibility check, concept validation.

Its allows the boundary for the part and the new features incorporated in it 

 

Fig 1  Master section.

 

 

MAIN TOOLING AXIS :

First to Create a tooling axis by given master section. Extract two parallel in master section with that we can Bisecting these lines to create a main tooling axis. By doing pre draft analysis in A surface with main tooling axis we can identify weather our tooling axis is correct ot not.

 

Fig 2  Tooling axis creation.

 

It is considered as an arbitary tooling axis and made permanant after confirming a  draft analysis. Then it is made as permanent tooling axis after the draft requirement is satisfied.

 

 

PRE DRAFT ANALYSIS :

 

Below image we can understand our tooling axis was correct and we are getting desire analysis output report.

 

 

 

Fig 2  predraft analysisat 3 degrees.

 

 

 

 

Fig 4  predraft  at 2.8 degree analysis.

 

 

 

 

CLASS B SURFACE :

Offset the A surface 2.5mm and named it as a B surface. In B surface we can observe one patches. Inorder to fix this patches we need to sweep with references surface.

 

Fig 5  Class A offseted to make class B

 

 

Below image after sweep operation then join it together and named it as improved B surface.

 

Fig 6  Class B surface 

 

 

C SURFACE: 

 After creating A and B surface then we need to create C surface using A surface. First extract A surface then create a boundary in edges. Then these edges need to smooth curve then do the sweep. Finally join all the C surface.

 

 

Fig 7  Class C formed from sweep  surface.

 

 

JOINING A & C SURFACE :

 

The A surface and C surface is joined  to form a new surface to  trim it with B surface 

 

 

Fig 8  Class C and A join.

 

 

 

Fig 9  B surface extrapolated.

 

 

Fig 10 Trim surface A and C Join and   B surface extrapolated. 

 

 

 Fig 11  Final  Trim surface.

 

 

 

DRAFT ANALYSIS OF A PILLER

 

 

The draft analysis of the apiller is done and have been passed the required standards.

 

 

   Fig 12. The draft analysis of the apiller at 3 degree

 

 

   Fig 13. The draft analysis of the apiller at 2.8 degree

 

 

 

 

 

 

 

 

 

DOG HOUSE CREATION 

 

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.

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 houses are designed to avoid sink marks created on the class A surface by screw bosses and to solve the length issues when giving screw bosses which need to be assembled to other components.
• It is also useful when perpendicular screw bosses are required on the part to the tooling direction.

• Make a rectangle to enclosure by projecting the lines from the master section.
• Extrapolate the surfaces and trim it together to from the required surface.
• Close the top face by using multi section surface.
• Thicken it by 2.5 mm to the outward direction

 

 

 

Fig 14 Given design for dog house 

 

 

 

 

 

 

 

• Fig 15 Sketch for dog house.

 

Fig 16  Extruded sketch 

 

 

Fig 17  Trimmed surface

 

 

Fig 18  Offseted  surface.

 

 

Top surface is formed by creating sketch and extrapolating thew sketch.

 

 

• Fig 19  Sketch for dog house bolt fixing.

 

 

 

 

 

 

Fig 20 Top  surface creation.

 

 

The surface is thickened to the required thickness and made to a part body. Here 2.5 mm is the given thickness.

 

 

Fig 21 Thickening the dog house surface.

 

 

Fig 22 Drafting the outer  dog house part.

 

 

Fig 23  Drafting the inner dog house part.

 

 

Fig 24 Edge filleting the dog house part.

 

Fig 25 Thickening the  horizontal surface of the dog house surface.

 

 

Fig 26  Drafting the  horizontal surface of the dog house surface.

 

 

Fig 27  Thickening th vertical surface of the dog house surface.

 

 

Fig 28  Drafting the  vertical surface of the dog house surface.

 

 

Fig 29 Edge filleting the dog house part.

 

 

 

Fig 30 Splitting lower surface from  the dog house part.

 

 

 

Different views of the doghouse created

 

 

Fig 31  Front view.

 

 

Fig 32  Top view.

 

 

 

Fig 33   Rear view.

 

 

 

DRAFT ANALYS

 

The draft analysis of the dog house is done for the required draft and found satisfactory.

 

 

 Fig 34  The draft analysis of the dog house outer.

 

 

 

 

Fig 35  The draft analysis of the dog house outer.

 

 

Fig 36  The draft analysis of the dog house outer.

 

 

 

 

Fig 37  The draft analysis of the dog house inner.

 

 

Fig 38  The draft analysis of the dog house inner.

 

 

 

 

DIFFERENT VIEWS OF THE PART 

 

 

 

Fig 39 Isometeric view 

 

 

 

Fig 40 Front view 

 

 

 

Fig 41 Rear view 

 

 

 

 

Fig 42 Bottom  view 

 

 

 

 

Fig 43 Side view 

 

 

 

 

Fig 44  Top view 

 

 

 

 

TREE STRUCTURE 

 

 

Fig 44  Tree structure.

 

 

 

Fig 45   Tree structure.

 

 

 

 

Fig 46  Tree structure.

 

 

 

Fig 47  Tree structure.

 

 

Fig 48   Tree structure.

 

 

Fig 49  Tree structure.

 

 

Fig 50  Tree structure.

 

 

Fig 51  Tree structure.