Week 11 - Project - A pillar Design with Master Section

Objective: The main objective of this challenge is to understand the given master section to create a solid body and B-side features for a given class A surface, by considering all the design parameters.

Master Section: Master sections are the guides for design requirements which decide the component packaging after technical (Styling, Concept or Class-A) surfaces.

Overview: Here in this challenge, I created the solid part body from the class A surface and B-side features (Dog house) for the class A surface. The master section measurements are considered to make the solid part body and Dog house. Created a tooling axis by using the bisecting line method and created a side core axis for clearing the B-side feature of the dog house. The draft angle is provided to the dog house outer faces concerning the Tooling axis, and the draft angle to inside faces are provided concerning the side core axis. The draft angle for a solid part body is 3deg, the draft angle for the dog house's outer surface is 1.5deg, and the draft angle for the internal surface of the dog house is 0.5deg.

Tooling Axis creation:

To create the tooling axis, I used the 'bisecting' line method. Initially, I created two lines on the master section by using 'point to point line' and then I created a bisecting line at the centre of those two lines by using bisecting line option in the line command.

Point to-point lines on the master section:

Draft analysis for class A surface:

The craft analysis check is performed on the class A surface before we create the solid part from that class A surface, to check whether the given class A surface is drafted properly or not. The draft angle for a plastic component is 0.5deg to 3deg).

some faces on the class A surface are not clearing with a 3deg draft angle. I reduce the draft angle gradually to clear the faces which are not clearing with 3deg.

I gave a draft angle of 2.5deg and still some faces are not cleared later I gave a 2deg draft angle to check if all the faces are cleared or not. Still some faces are not cleared with 2deg also, so I reduced the draft angle to 1.9deg, with a 1.9deg draft angle all the faces in class A are cleared properly.

Class B surface creation:

To create the class B surface initially, I measured the thickness of the master section (2.5mm). I offset the class A surface 2.5mm to the inside direction. The styling fillets on the class A surface are not offset properly, it created the patch on the offset surface. I used the sweep command to close the patch on the offset surface.

Class C surface creation:

To order to create the class C surface, I used the sweep command. I sweep the class A surface edges along with referencing the surface for 4mm inside with 90deg. After the creation of the class C surface, the surface edges are needed to be extrapolated to intersect properly from all 4 sides. I trim the surfaces which extrapolated, to get the closed class C surface. I joined the class A surface and Class C surface to get a single surface of class A+C surfaces. I trim the Class B surface with class A+C surface join, to get the closed surface to create the solid body

Solid part body creation:

To create the solid part body, I used closed surface command in the part-workbench. I gave the closed surface as an input in the closed surface command.