Week 9 - Project 1 - Door Applique Design with Engineering Features

 AIM

To Create the Base Bracket Plastic 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. 

Create the Heat Stakes and the locators considering the design rules mentioned

Firstly, the connectivity of the given Class-A surface must be checked, and ensure that there are no gaps between the surfaces.

It is clear from the above image that all the surfaces are continuous without any gaps in between them.

We can further disassemble the boundary so that the continuity is clearly visible.

Creation of tooling axis for the given Class-A surface

• Tooling Axis direction is the direction in which the core and cavity open.
• The selection of tooling direction depends upon the product and the features of the product.

The tooling direction is selected by visually checking the part and in such a way that there are no additional side cores required for the molding process. This ensures proper clearance of the part after the process.

The above image shows the tooling axis created along the Y-axis after virtually checking for the suitable direction.

Class B surface

It is a surface that is below a certain thickness from the class A surface. The engineering features of the product are on the class B surface while the class A surface is the styling surface.

The class A surface is offset by 2.5mm and then is extrapolated to form the b surface.

Class C Surface

The Class C surface is the surface used to join class A and the Class B surface.

Class C Surface

The Class C surface is the surface used to join class A and the Class B surface.

The c surface is created by sweeping the boundary of the class A surface along the tooling direction.

The Class  A and the Class C surface are joined together and are trimmed with the class B surface to form the closed surface.

The surface is then converted to a solid body by the Closed surface command.

iSOMETRIC VIEW

FRONT VIEW

TOP VIEW

Creation of 2way and 4 way locators.

A plane is created parallel to the center point of the ZX plane on the support surface.

Sketches are created for the 4 way locators

The 4 way locators are then padded and fillets , chamfer are applied. the 4 way locator is then copied and translated to another location.

The sketches are made for the 2 way locators.

the 2 way and the 4 way locators are unite trimmed with the door applique.

Creation of Heat stakes.

points are created to place the heat stakes.

Sketches are created for the heat stakes.

The sketches are then padded and translated to various points.

The heat stakes are then union trimmed with the door applique.

Sketches are created for the hole on the door panel.

Holes are created on the door panel.

Draft Analysis

When developing parts for plastic injection molding, applying a draft (or a taper) to the faces of the part is critical to improving the moldability of your part. Without it, parts run the risk of poor cosmetic finishes and may bend, break, or warp due to molding stresses caused by the plastic cooling. Equally important, an absence of a draft may prevent parts from ejecting from the mold, damaging not only the parts but possibly the mold itself—a costly and time-consuming detour.

In CATIA the draft analysis can be found by Insert > Analysis> Feature Draft Analysis.

Generally, the nominal draft angle will be 3 degrees.

Draft Analysis for the class A surface.

Draft analysis of the component.

isometric view of the dppr applique.

front view

top view

The full specification tree is shown along ech steps.