Week 9 - Attachment Feature Creation - Challenge 2

Dog House Creation

Aim :

To create the Dog house for the Door Trim considering the design rules for Dog house creation and then perform the Draft analysis for the final component.

Objective :

• Create the Tooling axis by using the bisecting method.
• Design the class-B and class-C surface and join them.
• Create the solid feature by surface we create.
• Design required Dog House and analysis them.
• Perform the Draft analysis for the final component.

Theory :

Tooling axis :

Class-A surface is first analyzed to create the tooling axis or tooling direction that molds pull apart in injection molding. Tooling direction is important for plastic product design as it decides direction for mold seperation.

Step followed for creation of tooling axis :

• Reference point is first created on extracted surface.
• New axis system is deployed to plot clearance lines.
• The X-direction and Y-direction along the class-A were to create tooling axis.
• Graphic properties of tooling axis were change before publishing.

Draft Analysis :

The Draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees. A functional part for injection molding has to have Drafts facing both cavity and core sides to reduce the risk of damge to the parts and ensure ejection. And also important is to overcome the vaccume forces by letting air in between the metal to the plastic for the part to release properly. Adding maintaining a decent cosmetic finish.

Draft should be a part of design for manufacturing and plastic product Designer should be aware of its need at the outset of the design process. This allows considerations for design requirement to be taken into account.

Nominal values for Draft angle :

• 3 Degrees is the nominal Draft angle.
• 7 Degrees for textured surface.
• At the minimum of 0.5 Degrees can be manufactured by special tools. But it will increase the manufacturing cost.

Tooling axis creation :

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 cosidering this things for this class-A surface tooling direction will be in Y-direction. so we create the point on the falt surface as shown in figure.

Next step is create the reference axis from the X-direction and the point by using the sketch and bisecting line tools as shown in figure.

Next step is create the reference axis from the Z-direction and the point by using the sketch and bisecting line tools as shown in figure.

Now we need to get the main tooling axis extrude the two reference axis as shown in figure.

And now we got the intersection line by the reference surfaces so by using intersection tool got the tooling axis line as shown in figure.

Now hide the remaining things as shown in figure.

Change the properties of the line the color and line type to visible that line clearly as shown in figure.

Draft Analysis :

1. The part created has to be changed to material mode in display frame.
2. Compass is enabled and align it along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft angle.

Draft analysis for class-A surface :

Given Class-A surface :

Created Class-B surface :

Created Class-C surface :

Closed surfaces :

Solid part : created by the close surface tool.

Create Dog House :

Sketch for create Dog House :

Final component with Dog House :

Tree structure :

Analysis for the Dog House Dimensions :

The analysis for the dimension is the one of the very important analysis to avoid the problems in the injection molding process for the component dimensions. The problems like sink marks, flow lines, weld lines, warping. Then they create some standards for creating the Dog House. That standard dimension is as shown in figure.

Now we need to check our part by intersect line in the sketch environment as shown in figure.

Analysis and claculation : For Dog House

This analysis and calculation is done in excelsheet for better understanding the status.

Draft Analysis :

1. The part created has to be changed to material mode in display frame.
2. Compass is enabled and align it along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft angle.

Draft analysis for Final component :

From main tooling axis :

From Side core tooling axis :

Iso-metric view :

Front view :

Side view :

Top view :

Conclusion :

Hence the Dog House for the Door trim concidering the design rules for Dog House creation and then Draft analysis is also performed for the final component succesfully done.