Week 12- Final project

FINAL PROJECT

AIM :

To create a door interior part from the inputs of class A surface along with master section by following the design rules followed in tier 1 and OEM industries in catia v5.

GIVEN DATA :

Creating a tooling axis in class A surface :

• The direction in which the mould open and closes is the tooling axis.
• Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
• While creating a tooling axis give the tooling axis on a flat length surface or the surface which have a hole on it.
• Create a point on the surface where we are going to create the dummy tooling axis and using line command crate an axis. If there is a circle or flat length surface which is recommended.

Draft Analysis :

• The draft analysis technique is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied.
• Minimum draft angle is considered as 3 degree.
• step 1= enter part in Catia.
• step 2= Go to Material Mode.
• step 3= go for draft analysis.
• step 4= drag axis bar to the tooling direction of part.
• step 5= check for draft and make parting line as per analysis.

Create a class B surface :

• Class B surfaces are the secondary surfaces in plastic component design.
• In this model Class B-Surface is extracted from the A-surface and it is offseted at 2.5mm in downward direction.

Create a class C surface :

• Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic finish.
• C-Surface connects the class A-Surface and B-Surface. It is created using Sweep command.
• Boundry of the class A-Surface is swept along the tooling direction.

DOG HOUSE :

• Dog house is an engineering feature used in plastic trim design. Dog houses are used as supporting feature. Sometimes other engineering features like snaps; locators etc. are mounded on them to increase their strength.
• Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity. Dog house and other engineering components are built on B-surface.
• Thick sections waste material and are simply uneconomic. So solid shapes that would do the job well in wood or metal must be transformed to a 'shell' form in plastics.
• Tooling must be cleared for easy ejection of the component, from the core cavity. In order to clear tooling certain value of draft is given to the component. Minimum of 2-3deg is provided on all plastic components.

LOCATORS :

• Extract the surface that we going to create locator
• Use positiioned sketch and draw a locator sketch
• Use pad commands for the sketch to till we required
• Draft the locator for minimum of 0.5 degree
• Add fillet 0.5mm o all faces
• Assemble the locator to lower subtrate solid
• Maintain a 50mm minimum between two locator
• Translate the locator to wherever we need
• Trim the all heat stakes with lowersubstrate solid
• Maintain a height more than heat stake

Sketch Plane is made in the tooling axis direction.

Height = 24 mm

Wall Thickness = 1.3 mm

Draft Angle = 0.5°

Chamfer = 3 mm, 45°

Fillet 0.3 mm & 3 mm

HEAT STAKES :

Heatstakes is known as thermoplastic staking is the process of joining two dissimilar metals together

• Extract the surface that we going to create heat stake
• Use positiioned sketch and draw a heat stakes sketch
• Use pad commands for the sketch to till we required
• Draft the stakes minimum of 0.5 degree
• Add fillet 0.5mm o all faces
• Assemble the heat stake to lower subtrate solid
• Maintain a 50mm minimum between two heat stakes
• Translate the heatstakes to wherever we need
• Trim the all heat stakes with lowersubstrate solid

Sketch Plane is made in the tooling axis direction.

The length of heat stakes should be at least 5 mm lesser than locators, L = 19mm

Radius, ID = 4.5mm, OD = 7.5 mm

Draft Angle = 0.5°

FLANGE :

Create flanges arm rest, lower map pocket and upper map pocket garnish for attachment of heatstakes and locators at lower substrate.

FINAL PART BODY :

FINAL DRAFT ANALYSIS :

FINAL OUTPUT FROM DIFFERENT ORIENTATION VIEWS :

TREE STRUCTURE :