Week 12- Final project

Step 1: Creation of Product File and Part File

• The door trim panel contains input of different surfaces.
• To work on these surfaces one new product file under assembly workbench is open.
• In this product file new part are added and the surfaces from original part file are separated and named as Master Section, Arm Rest, Lower Substrate, Map Pocket and Bottle Holder respectively.
• Another part file Push Pin which was already given as input is added.

Step 2: Creation of A Surface Improvement

• All A surfaces are checked for any irregularities by using boundary command.
• It is found that in Arm Rest and Lower Substrate surfaces contains gaps which was resolved using join, sweep and trim commands.
• After obtaining the improved A surfaces further chain of commands were performed on respective product files.

Arm Rest A Surface Improved

Lower Substrate A Surface Improved

Step 3: Creation of Tooling Axis

The Tooling Direction is the direction in which mould pulls a part. The mould is built with two unconnected parts named as Core and Cavity. The Core and the Cavity are pulled apart along the Tooling Axis in the Tooling Direction.

• For the given input check the best possible tooling direction.
• Extract the lines from master section and use bisecting lines to generate tooling axis.
• Bisecting Line were used to get the exact medium from the two lines so that maximum positive draft angle can be achieved.
• The Tooling Axis was generated on the direction where maximum surfaces are clearing.
• Tooling Axis was generated for all Arm Rest, Lower Substrate, Map Pocket and Bottle Holder respectively.

Step 4: Performing the Draft Analysis

The draft analysis technique is used to analyse whether the part model created in CAD is manufacturable or not based on the draft condition applied. This type of analysis is performed on the basis of colour. Different colours identify different zones on the analyzed element. On the basis of colour deviation from the draft direction at any point can be visualized and if necessary, the main component could be adjusted. It can correspond to specified values which are pre-defined.

• For performing the draft analysis check the customized view parameter and under mesh select material.
• For draft analyses use the compass to define the draft direction.
• In the colour scale make the draft angle to 3⁰ for performing draft analyses.
• If the component changes to green it indicates of passing draft angle.
• The Draft Analysis is complete now.

Arm Rest Class A Draft Analysis

Lower Substrate Class A Draft Analysis

Map Pocket Class A Draft Analysis

Bottle Holder Class A Draft Analysis

Step 5: Creation of Side Core Axis for Arm Rest

• In Arm rest part file, it was found all surfaces were not clearing the tooling axis.
• So, for Arm Rest side core tooling axis was created along the perpendicular direction of tooling axis.
• This side core tooling axis will be used for performing draft analysis for the Arm Rest area which cannot be cleared in the normal tooling axis.

Arm Rest Class A Draft Analysis of Side Core Axis

Step 6: Creation of Class B Surface

• For generating the Class B Surface offset the Class A Surface for the value of 2.5 mm.
• Complete the Class B Surface using sweep, join and trim command.
• Extrapolate the Class B surface as necessary so that it gets trim with the join of Class A & C surface.

Step 7: Creation of Class C Surface

• For the creation of Class C surface use Class A Surface, for obtaining the boundary using boundary command.
• By using Sweep command create C Surface using 3⁰ as draft angles or 90⁰ along the A surface whichever is suitable.
• Join the Class A & C surface properly checking for any gaps.
• If there are gaps extrapolate Class A Surface and Sweep both sides and trim them.
• This trim is the Class A and C Surface.
• Extrapolate the surface if necessary to perform trim.
• After getting the output trim it with class B surface to get final output.
• Create the solid component by switching to part design workbench and using close body surface.
• Perform Draft Analysis on closed body.

Arm Rest Closed Body Draft Analysis

Arm Rest Closed Body Draft Analysis of Side Core Axis

Lower Substrate Closed Body Draft Analysis

Map Pocket Closed Body Draft Analysis

Bottle Holder Closed Body Draft Analysis

Step 8: Creation of Heat Stakes

Heat Stakes are the components which are used to connect to parts of the product.

• In Lower Substrate the heat stakes are generated along side the boundaries of Arm Rest, Lower Substrate, Map Pocket and Bottle Holder respectively.
• Heat stake are made using master section as provided in the input.
• Using master section as reference create a sketch using positioned sketch and by giving proper constraints make it Iso-constraint.
• After creation of the sketch, pad it for the required height.
• Draft it 0.5⁰ alongside the direction of the tooling axis using neutral element as base.
• Using multiple extract command extract boundaries where heat stakes are needed to place.
• Apply parallel curve command and create the path way for placing heat stakes.
• Use multiple point command to create points on parallel curve placing at minimum distance of 50mm.
• Copy heat stakes using paste special so all the heat stakes can be edited, if necessary, at once.
• Translate the heat stake on these points.
• Some of the points will be used for placing locators.
• Union trim the heat stakes with the main surface defining the face to keep/ face to remove to get the final output.
• Perform draft analysis with draft angle as 0.49⁰.

Step 9: Creation of Four Way Locator

Locators are used to secure two components in connectivity with each other.

• In Lower Substrate the locators are generated alongside the boundaries of Arm Rest, Lower Substrate, Map Pocket and Bottle Holder respectively.
• Create a 4-way locator using a sketch on the body and give proper constraints to make it Iso-constraint.
• After creation of the sketch, pad it for the required height and thicken it for 1.3mm at neutral fibre.
• Draft it 0.5⁰ alongside the direction of the tooling axis using neutral element as base.
• Give 3mm of chamfer with 45⁰ of inclination and a fillet of 3mm radius on chamfer. Give fillet of 0.5mm on all faces.
• Copy locators using paste special so all the locators can be edited, if necessary, at once.
• Translate the locators on the remaining points of heat stakes.
• Union trim the four way locators with the main surface defining the face to keep/ face to remove.

Draft Analysis for Heat Stakes and Four way Locator

Step 10: Creation of Side Core Axis

• Create a line along the perpendicular direction of tooling axis.
• Use the points from the given inputs of master section.
• This is side core tooling axis which will be used for giving draft for the dog house.

Step 11: Creation of Dog House

• In Lower Substrate the Dog house are generated as required.
• Create the drawing for dog house and give proper constraints to make it Iso-constraint.
• Sweep the dog house for draft angle of 1.5⁰ along the tooling axis and use thick surface to make dog house.
• Perform split give final Draft value using pulling direction as side core axis and fillet on the dog house.
• Copy Dog house using paste special so all the Dog house can be edited, if necessary, at once.
• Translate the Dog house on the required places and rotate them as required for proper positioning.
• Union Trim the Dog House with the main body to get final output.

Draft Analysis for Dog House Along Tooling Axis

Draft Analysis for Along Side Core Tooling Axis

Step 12: Creation of Flanges

• In Arm Rest, Map Pocket and Bottle Holder respectively flanges are generated as required.
• Create the drawing for flanges using master section as reference and give proper constraints to make it Iso-constraint.
• Sweep, extrude and trim to obtain the final surface of flanges.
• Use thick surface to make flange a solid body.
• Paste the flange for all heat stakes and four way locators.
• Generate a line parallel to the surface of flange using positioned sketch command.
• Extrude it to the perpendicular of flange surface and offset it to obtain individual flange for heat stakes and four way locators.
• Create circular hole on each flange as required for heat stakes and four way locators.
• Union Trim the flanges with the main body to get final output.

Arm Rest

Lower Substrate 

Map Pocket

Bottle Holder

Step 13: Creation of Assembly

• In product generate the reference as the base for the assembly.
• In this the Lower Substrate is used as the reference elements and fixed.
• By using constraint command apply the constraints and assemble the products.
• Create coincidence constraint between dog house and push pin to align them.
• Now apply surface constraint so push pin will sit on the dog house properly.
• Use the save management command to save all the files.

Assembly Constraints

Assembly Isometric View

Assembly Multi View