DOOR TRIM – DOG HOUSE CHALLENGE - 2

OBJECTIVE:

To create the B, C surface from given Class A surface and design Dog House in Door Trim.

DESIGN METHODOLOOGY/APPROACH:

Reference Image:

Draft Analysis:

Draft analysis is the analysis to examine whether the designed part is exit from the mould smoothly or not. Generally, 3 degrees from the Class A surface to be drafted. In the below diagram draft analysis is performed by given Class A surface.

Draft Analysis of Class A:

Draft analysis of Door Trim component:

Tooling axis:

Axis which drafts the part from certain angle is called tooling axis. Initially the part is checked in all direction for tooling axis, the suitable direction for tooling to be selected considering reduce the mould cost. In this part considering all axis Y axis is best for tooling. But there is Axis system is insert in the base surface with point create the line which is parallel to Y axis, then using of intersect command intersect the given class A surface draw the line from centre with angle and made the bisecting line by created two lines. Finally, the tooling axis line by using bisecting line and points.

The drawn tooling axis is shown below.

Making of B,C Surfaces:

B Surface:

B Surface is made by offset the Class A Surface by 2.5mm thickness, then fill the gap and join it. Then extrapolate the surface for trim. The following images shown the steps for B surface.

C Surface:

C Surface is made by extracting the boundaries of class A surface individually and sweep them by 3 degrees, then fill the gap and added.

Then added it with A Surface. Finally trimmed it with B Surface to get final surface.

Adding body to define it and make them closed surface to make them solid body.

Making of Dog House:

Initially extract the base surface and draw a Sketch which is shown in figure.

Then the sketch is extruded with tooling axis and close the upper surface.

The surface is thickened by insert body and defined it. Then the outside two faces are drafted in 1.5 degree and inside two faces are drafted in 1.5 degree. Fillet 1 mm given in inside edge.

Another Axis is create to draft the inner face in 0.5 degree by drawing line in the point which create the Tooling Axis in X direction. The below images are shown part images as Surface image.

Then extract inner surface with tangent and offset into 1mm (C = 0.4t = 0.4*2.5 = 1) and offset the base surface in 4mm (B = 3to6 = 4) for side core cut.

Offset surfaces are trimmed to get the side core cut surface.

The surface is filled and extrapolate to cut the bottom of dog house by shown in image. It is done by split command.

Then the part is Assembled in the main Door Trim Part body and giving fillet in corners. The door trim having Dog House are shown in below image.

Then the Dog House part is copied and by paste special command the part is translated in another required place. The final part having Dog House is shown below.

Finally published the A, B, C Surfaces, Tooling and Side core Axis.

Conclusion:

By using above methods Door trim with Dog House is designed.

Sketch 1 fully defined:

Expanded tree structure 1:

Expanded tree structure 2:

Expanded tree structure 3:

Expanded tree structure 4:

Expanded tree structure 5:

Isometric view:

Front view:

Side view:

Top view: