Week 9 - Attachment Feature Creation - Challenge 2

AIM

To create the Dog House for the Door Trim considering the design rules given.

REPORT

1. Creation of tooling axis

• At first we check the class A surface is ok by using the boundary option.
• After that we extract the base surface which identified as the best place for tooling axis to pass through.
• Create a point on the center of that surface.
• Draw a dummy line perpendicular to the surface passing through the point.
• Create a plane parallel to the curve and use intersection option to create the intersection line.
• Indentify the points or place which could cause trouble while moulding.
• Draw a line on both sides as below.
• Now using bisecting line method create a bisecting line passing through the point.
• This line is our tooling axis.

2. Draft analysis on class A

• Open the draft analysis toolbar.
• Click on the compass icon and drag and place the compass on tooling axis.
• Click anywhere on the body to run the analysis.
• From the image we can see that the class A clears the tooling parametrs.

3. Creation of B surface

• To create the B surface, first we offset the class A inside by 2.5mm.
• Check for any patches are formed on the surface

• Using the boundaries, multi section surfaces, trim, extract, multi extract, extrapolation and join operation we create the B suface by fixing all these pathces.

4. Creation of C surface.

• Identify the sharp corners in the Class A surface.
• Accordingly we create multiple sweeps depending on the number of boundaries.
• In difficult sections, we use multi section surface command.
• Exrapolate all these sweeps at their ends.
• Trim them to get the C surface.

5. Final Join

• At first join both the A and C surface.
• Then extrapolate all the sides of class B to a min distance.
• Then using the trim option, we join both B and A+C surfaces.

6. Creation of closed surface.

• Open the part workbench.
• Click on closed surface option.
• Click on the object and the final body is generated.

7. Creation of Dog House

• Create a point on the surface where you want to place the dog house.
• Create a plane parallel to yhe curve at that point.
• Draw the positioned sketch of the dog house.

• Extrude the sketch to 20 mm and 1 mm on the other side.
• Using multi section surface, close the top region and join them.
• Go to part design and thicken the surface for 2mm in outside direction.
• Using split option rmove the excess region with the help of extract, untrim, extrapolate and offset.
• Give a draft angle to the outer walls for 1.5 degrees using main tooling axis
• Then give a draft angle for 0.5 degrees on the inside using side core axis
• To create the dog house wall thickness, first we extract the top wall of the inner surface.
• Then using multiple extract we extract the remaining inner walls.
• Then offset the extract of the top wall downwards to about 16mm.
• Then offset the outer walls outside for 1.5mm.
• Then extrapolate the offsetted top wall.
• Then trim these two surfaces.

• Go to part design and split them
• Fillet both the inner and outer surfaces to get the dog house
• Copy and paste the part design
• Now using transalation option create another dog house at any desired distance.
• Now using union trim boolean operation, join these two dog houses with the main body.

8. Draft analysis on the final component

• Open the draft analysis toolbar.
• Click on the compass icon and drag and place the compass on tooling axis.
• Click anywhere on the body to run the analysis/
• From the image we can see that the final component clears the tooling parametrs.

RESULTS

1. ISOMETRIC VIEW

2. FRONT VIEW

3. SIDE VIEW

4. TOP VIEW