Week 9 - Attachment Feature Creation - Challenge 2

Week 9 - Attachment Feature Creation - Challenge 2

AIM:

• To Create theDoor Trim Component from the given Class-A surface.
• To Create the Tooling axis for the given Class-A Surface meeting the requirements of the draft angle.
• To perform the Draft analysis on the model.
• To Create the B Side Feature in the component by following the design rules.

INTRODUCTION:

DOG HOUSE

Dog house is an engineering feature used in plastic design. Dog houses are used as support feature. Sometimes other engineering features like snaps, locators, and screw bosses are mounted on them to increase their strength.

Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mould cavity. Dog house and other engineering components are built on the B-surface.

OBJECTIVE:

• Create the Tooling axis.
• Design the class-B and class-C surfaces and join them.
• Use the Close Surface feature to make a solid body from the surface.
• Design the required dog house and analysis them.
• Perform the Draft analysis for the final component.

INPUT :

CLASS A SURFACE

DESCRIPTION:

CREATING TOOLING AXIS

NORMAL TO SURFACE

The Tooling Direction is basically the direction that the mold pulls a part. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dye line or the Tooling Direction.

MAIN TOOLIONG AXIS

The first step is to observe the given class-A surface deeply and we can say the larger flat area which is perpendicular to the Tooling axis. So, by considering this thing for this class-A surface tooling direction will be in the X-direction. so we create the point on the flat surface as shown in the figure.

SIDE CORE AXIS

BISECTING METHOD FOR TOOLING AXIS

• Check for gaps between surfaces for that click on join and then preview.
• If theres any gap between the surfaces join them with a maximum tolerance of 0.003 mm.
• Extract the boundary and dissemble the boundary.
• Find the correct tooling axis where the material don't interfere with the tooling axis and all the elements can be created.
• Intersect the yz plane with respect to the class A surface.
• Hide the class A surface and create point to point lines on the suspected drafts.
• Create bisecting line with the two lines and point to create a tooling axis.
• BISECTING LINES were used to get the exact medium from the two sides so that maximum positive draft angle can be achieved.
• The tooling axis is created for the component.

DRAFT ANALYSIS FOR CLASS A SURFACE

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

• Before going to drat analysis go to customized view parameter >under mesh >check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compasss to define the draft direction.
• In the colour scale change the draft angle to 1.45 degree.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.

CREATING CLASS B SURFACE

• Extract the surfaces from the class A using multiple extract and untrim them.
• Use Extrapolate to make sure that all the untrims are properly intersected to trim and offset the surfaces to 2.5 mm to create the thickness.

• Trim the extra surfaces using trim command.
• Insert them into new geometrical set and name it with respective part names.
• Apply fillets to the model after creating the entire surface.
• If the edges are outside the fillet value will be added to the thickness of the component and if the edges are inside, the fillet value will be subtracted from the thickness of the component, for instance the thickness of the component Is 2.5mm the fillet value is 15mm so the outside portion value should be 17.5mm and inner eges should be filleted 12.5mm to get uniform thickness.
• Perform trims one at a time so that it will be clear to understand.

CREATING CLASS C SURFACE

• Extract the boundary from the class A surface using boundary command.

• Using disassemble tool to divide the boundary as the boundary contains domains.
• Use sweep command > choose profile type line > subtype as with draft direction > choose guide curve and draft direction > draft angle as 1.5 degree > preview.0

• After getting sweep then trim the output with class B surface to get final output.
• Now open part design workbench and using close body surface create a solid of the component.

CREATING CLOSED SURFACE

• For creating the Finals door trim surface, join the CLASS-A and CLASS-C surfaces together.

• Then Extrapolate the B surface a little bit outward direction to make sure that there would not be any gap when trimming with the joined surface.

• Then trim the extrapolated CLASS-B surface wthe ith Join surface (CLASS-A and CLASS-C).

• Make a solid part body using the close surface command in the part design workbench.

B SIDE FEATURES CREATION

Design Principle for Dog House Creation

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• The height of ( B ) should be between 3.0 – 6.0 mm .

DOG HOUSE CREATION

• Extract the flat surface.
• create the plane at the point which we create on surface.
• Draw the required fully iso constrained sketch on plane as shown in below picture.

• Create the dog house by creating a positioned sketch on the z-x plane. Using extrude or sweep method create dog hose outer walls.

• Now close the top wall using the multi-section surface command.

• Using thicken command in the part workbench, create a solid part of the dog house.
• Give proper draft angles and fillets by considering the design rules.
• Using Boolean operation, union trim the dog house body part with the door trim component.

• Repeat the procedure at required place to create another dog house.

DRAFT ANYLISIS FOR FINAL COMPONENT

DRAFT ANYLISIS FOIR DOG HOUSE

CLOSED BODY

FRONT VIEW

SIDE VIEW

TOP VIEW

ISOMATRIC VIEW

ALL VIEW

FEATURE TREE

CONCLUSION:

I have successfully created CLASS B and C surfaces using the given CLASS A surface of the door trim created main and side core tooling axes. Performed draft analysis the the final component and the dog house.