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

ARM REST

IMPROVED CLASS A SURFACE

for arm rest by analysing the master section there is a space for the outer material before the class A
that is for the leather finish
the distance between leather finish the and the Class A is 2 mm and the thickness of the component will be 2.5 mm
so offset the given surface to 2mm wrt master section
from that offset some of the values will be lost
so as to cover the lost portion we want to extract the surface that is lost from the given surface and offset that to 2mm
and extrapolate them and trim to get a connected surface
then for the top fillet extract the boundaries and do a sweep or multi section surface for the fillet
personally i had done multi section surface
extrapolate and trim the multi section surface with before trim
join the final surface with the Class A surface
That surface will be our Improved class A surface

STEPS TO FOLLOW

STP file to product conversion
Tooling Axis Creation
TOOLING AXIS CREATION
- select a tooling direction and select a surface for a point
- make a line perpendicular to the surface
- if that line passes the draft analysis that will be our MAIN TOOLING AXIS
- then create a line parellel to the surface from the same point
- that will be the SIDE CORE TOOLING AXIS
Preaparation of class B and Class C Surface
CLASS B SURFACE
from the master section given the thickness of the component is 2.5mm
that will be offseted from the improved class A
in that offset also there will be some of the surfaces missing
for compensating that lose we want to do as same as we had done for the improved class A
and finally join that surfaces together with maximum deviation of 0.01/0.1
check the boundaries are correct

CLASS C SURFACE CREATION

from the improved class a surface findout the boundaries that can be sweeped with draft direction and others with reference surface
divide those with the help of perpendicular end and parellel end
then sweep accordingly
if there is any complicated curves or retractions create a spline from the end points of nearest sweep and support as outer ends
then extract the other 3 boundaries
do multisection surfaces with the sweep side extract as profile and guide curve as spline and boundary
then join those with max deviation .1mm
do this procedure for any complicated surfaces
trim every sweep surfaces with each other

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

RESULT

The A surface of the following components converted to a solid body:
- Straight Arm Rest
- Inclined Arm Rest
- Upper Map
- Lower Map Pocket
- Lower Substrate
Each component has a uniform thickness of 2.5mm.
The components' surfaces (A, B & C) pass for Drafting analysis.
The Plastic features follow the design guidelines and pass for the Lifter draft analysis.
Clearance is provided on the Flanges, allowing for the Heatstakes to arrest and form an Assembly.

ARM REST

FEATURE TREE OF ARM REST-

DRAFT ANALISISE-

BOTTLE HOLDER-

DRAFT ANALYSIS

LOWER SUBSTATE-

FEATURE TREE-

DRAFT ANALYSIS OF LOWER SUBSTATE-

TOOLING AXIS OF DOOR TRIM ASSEMBLY-

Ship work like this
in your own course.