Challenge

Week 12- Final project

AIM: To create a CAD model considering the OEM standards from the Class-A surface of a Door Panel.

So we have given 4 class A surfaces of a door trim ,which are lower substrate, arm rest, bottle holder and map procket

STEPS TO FOLLOW

Step 1, STP file to cat product conversion

Step 2, Tooling axis

Since we have no master section given we can go with the point and direction method
All the parts will have uniform tooling axis direction, else it ll be difficult to assemble, except arm rest all parts are good in y direction
so in arm rest we ll keep a side core axis in y direction, main tooling axis in z direction

Step 3 and 4

ARM REST

Insert a new geometrical set for tooling axis , extrcat a surface use point and direction method to create the main tooling axis and side core axis in y and z direction respectively
do the draft analysis make sure no problem with the class A
Create a G. set for class B
offset class A by 2.5mm , Modify the class B using split and spline to replicate class A ,do the extrapolation of class B

CLASS C

FINAL TRIM

After getting A+c surface do the intersection with B and check whtether any gap is there or not
Do the trim of B with A +c

CLOSED COMPONENT CREATION

After getting final surface do the closed surface tool in part worknench

DO the DRAFT ANALYSIS
draft anlysis i snot clearing properly, arm rest will be 2 sufaces but here we have given as a singler surface that is why draft analysis is not clearing with the tooling axis

CREATE THE OTHER 3 CLOSED COMPONENTS IN THE SIMILAR WAY

ENGINEERING FEATURES

HEAT STAKES

Activate lower substrate part
Insert a new geometrical set for Engineering features, insertr another in it For Heat stakes
Now create a point and a plane at the base of the heat sytake , extract the edge for point
Isolate the point and provide the coordinates
Create a sketch on the plane by taking reference from master section
isolate the reference
extend it , close it provide the dimension
create axis for shaft
insert a new body for heat stake
provide fillet at top edge of 0.25mm
No needto provide the draft since it is directly provided in the mastersection

RIBS ON HEAT STAKES

PLACEMENT OF OTHER HEAT STAKES

Take the distance between centre part of heat stake with edge of the fillet nearby , it is 9.953
dont take any refrence from solid , unhide the b surface
Define heat stakes G .set and take the multiple extract of the edges of b surface
Now we need to use parallel curve tool to offset the previous curve by 9.953
now we need to create multiple points in equal distance, (50-75 mm)
Using same procedure, create the curves and points for the placement of heat stakes and locator at the map procket and lower substrate
Copy the heat stakes and use paste special to paste
Use translate tool to translate the heat stakes

For creation of locator,

DOG HOUSE CREATION

Take the extract of final trim of lower substrate
create a point and a plane normal to tooling axis
inser a new G. set for dog house
create a sketch of 30*30 mm , provide 2nd limit of 2 mm
decide which side is to be open
insert a body , then pad
provide draft to alll three walll except the front with 1.5 degree
provide shell with 2.5mm as thickness
Since dog house is an internal undercut we need a side core axis to manufacture
Before creating the side core axis, do the draft anlysis for outer surface of dog house , whether it is clearing in 1.45 degree or not
create the side core axis and do the draft analysis find out which surfaces need to provide the draft angle
provide the inside draft angle of 0.5 degree
check the draft analysis and make sure all inside surfaces are clearing or not
Inorder to avoid sink marks we have to modify the dog house by providing coring
Create a sketch on the same plane according to the design considerations
insert a body , coring and pad it (3- 6mm), provide the 2nd limit of 2mm
Provide draft for all the side wall of 1.5 degree with respect to the main tooling axis
Time to remove the extruded part from thdog house
then do the draft analysis , if not clearing do the draft of 0.5 degree with respect to side core axis

RIB CREATION DOG HOUSE

Create a plane on the same point normal to tooling axis
create a sketch , line , insert a body, pad it with 1.5mm thickness and some height
draft w,r,t to tooling axis of 1.5 degree and w.r.t to side core with 0.5 degree
provode fillets
do boolean with dog house

FLANGE CREATION

Flange shape will change w.r.t to placemenent , Height will change so we cant copy and paste it, we have to create ittt seperately
there a re 8 -10 steps for creation of flanges
Point and plane creation
Create a plane paralle to the yz axis on the centre point of mastersection created in lower substrate
isolate the point and change the definition to coordinates
take the multiple extract of c sutface, since the flange will be created from the c surface of counter part
only take mutiple extract from final trim
take the intersection with the plane and the extract
create a sketch
sweep with profile as sketch and guiding curve as the multiple extract edgess of final trim
do the trim and make solid using thick surfacess
provide draft of o.5 degree
provide fillets
Now hole creation is left
define the flange create a sketch of circle with dimeter 8.5 (7.5 +0.5+0.5)
pad it and provide the draft, using boolean remove it
provide the final fillets
do the draft analsysis

ASSEMBLYING OF PUSH CLIPS ON THE DOG HOUSE

Ship work like this
in your own course.