Week 9 - Attachment Feature Creation - Challenge 2

Aim:

      To Create the dog house for door trim 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. 

Objective :

• To design door trim as per automotive OEM Standard.
• Create B Class and C Class and tooling axis.
• Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
• Performing draft analysis to verify the creation of the Tooling axis and C Class surface.
• To create dog house using guidelines.

Operations :

• Creating tooling axis.
• Create draft analysis
• Creating Class B surface.
• Creating Class C surface.
• Final product using closed surface.
• Creating Dog House.  

MATERIAL USED :

Acrylonitrile butadiene styrene(ABS)

Door trim is manufactured in plastic materials such as ABS. ABS plastic remains hard, rigid and tough even at low temperatures. It is available in fire-retardant, heat-resistant and platable grades. It is found inside the car.

Tooling Axis: 

Tooling Axis is created on the surface along which a point is created on the centre of the surface and a line is extruded along the y axis. The tooling axis determines the direction of the core and cavity moves.

Draft analysis:

      Draft analysis is a angular tapering given at the design stage to every plastic component that has to be manufactured. For this design we have given the draft angle of 2.9degee which is widely accepted for cost saving purpose.

                              DRAFT ANALYSIS FOR CLASS A SURFACE

                                     FINAL DRAFT FOR CLOSED SURFACE

Draft Analysis for Dog house:

 Draft analysis for dog house is created in two axis x and y. The internal cut is made in the molding process is lifter and the draft angle is x axis and given as 0.5 deg. External cut is made by slider and the draft angle is y axis and given as 1.5 deg which  is ejectable from the mold.

                                OUTSIDE DRAFT FOR DOG HOUSE

                                      INSIDE DRAFT FOR DOG HOUSE

                           OVERALL DRAFT FOR DOG HOUSE AFTER SINK MARK

Class A surface:

      Class A surface is a any set of freefrom surface of high efficiency and quality. It is the aesthetic surface pf any automotive component. class A surface is visible to eye .It is given as input to design the Class B&C surfaces.

Class B surface:

      Class B surface is invisible to the eyes or it is often found in back side of the Class A surface. It is mainley the thickness of the component and the thickness of the component is 2.5mm thickness.

Class C surface:

       Class C surface connects the surface between Class A and B surface. This surface connects both A & B surfaces along the tooling axis. It is the thickness of the Class A&B surface.

Class A&C Join:

Final Product:

       Final Product includes the finished surface of class A & B and C. 

Closed surface:

  Closed surface is the finished product using part body design with closed body surface command.

Dog House:

Dog house is a feature used as supporting featrue in the plastic trim.It is used to avoid sink mark.

Guidelines to create dog house:

1. width of the dog house -(25-35mm).
2. height of the dog house -(45-60mm).
3. outer draft -(>0.3 deg), nominal =1.5 deg.
4. inner draft -(>0.1 deg), nominal =0.5 deg.
5. Thickness -Nominal wall thickness.
6. Height of the sink mark cut-(3-6mm).
7. Fillet can be according to then drawing.
8. Length of one dog house to anotherdog house is (w x 3).

Dog House Sketch:

               DOG HOUSE

Closed Body:

Tree Structure: