Week 8 - Challenge 5 - Door Trim Lower

AIM :- To create the Door Trim Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Given :-

Thickness of the component = 2.5 mm

CLASS A SURFACE -

The A-surface or the styling surface is first checked for any gaps and other issues in its surfaces. This Surface acts as the input surface so any correction to be done should be with approval from the styling team or done by them. A- perfect surface is the one when a boundary is created, the lines are only on the edges of a component and its holes or cutouts as shown below.

CREATION OF TOOLING AXIS -

Tooling axis is the direction in which a core or cavity of mold opens. This Axis is very important to determine the orientation of the component in mold, core and cavity design.

The tooling axis is created by Bisecting line method. For that first I have drawn X and Z-direction clearing lines and then I draw bisecting line with the help of these two.

DRAFT ANALYSIS ON CLASS A SURFACE -

Draft analysis of the surface is carried to check if the surface or part can be manufactured with the required draft angle.

Draft angle is needed for the component to clear the core and cavity surface as it would have shrunk towards the center while cooling.

The draft angle in this design is 3 degrees. As A surface is a single surface there won't be much difference in color. The draft analysis of A-surface is shown below.

CREATION OF CLASS B SURFACE -

The A-surface is offsetted by 2.5 mm as it is the thickness required.

The offset surface is the B-surface but had some issues like in some areas shown in below images.

By using blend operation I close this missing surface. But for creating edge fillet I have follow proper procedure and gived edge fillet.

The following image shows the missing surfaces get closed.

Creation of edge fillet on class B -

First I have removed the edge fillet by using join operation and disambled above surface into two separate surfaces.

Then I have extrapolated joining boundary of these two surfaces and after trimming these two I have given edge fillet at joining.

For second edge fillet I followed same procedure that shown in following image.

Then I have extrapolated outer boundary of Class B.

CREATION OF CLASS C SURFACE -

The A and B surfaces are connected by another single surface which is called the C surface.

It is created by using sweep with A surface acting as the reference surface and curve created from the boundary of the same surface.

Sweep with draft direction is also used to create A-surfaces.

CREATION OF CLOSE BODY -

All the surfaces (A,B,C) are joined together to form a closed body.

CREATION OF SOLID BODY -

I used the Close Surface feature to make a solid body from the surface.

DRAFT ANALYSIS ON SOLID BODY -

The final solid part body has to be analyzed using Draft analysis. This is done to check if all the areas of the body are satisfying the draft angle which is 3 degrees.

A draft angle is a taper applied to the vertical walls of the injection-molded component to assist with releasing the part from the mold.

Draft angles are a required feature of injection-molded custom parts. A functional part for injection molding has to have draft angles that face both the cavity and core sides. This will reduce the risk of damage to the parts and ensure that they can be ejected from the machine.

The Door Trim body is checked using Analysis and images for it are shown below.

CONCLUSION -

The Draft analysis of the component shows that the component is feasible to be molded without any issues.

Thus it satisfies all design and manufacturing criterias needed for a proper part.