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

AIM :

To create a door applique design from the given class A surface and create engineering features.

PLATFORM USED : CATIA V5

INTRODUCTION :

HEAT STAKING :

Heat staking is a pulsed heat process to join two or more part out of whish one at least is made of plastic .The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order to fix the other.

Heat staking makes it easy to bond metal to plastic and it is commonly used in hight volume/low-cost application such as automotive,IT and consumer application.

In manufacturing of thermoplastic component,it is often necessary to join the thermoplastic to a part of dissimilar material,whether it can be metal,dissimilar material or the other material.Thermal staking is an assembly method that used the controlled melthing ans reforming of plastic stud or boss to capture or lock another plastic or a metal compponent of assembly in plastic or metal compionent of an assembly in place.The heated thermal cotact the top of stud,which melts and fills the volume of tip cavity to produce the head,locking the component in a place.The progressive melting of the plastic under continuous pressure from the head.when staking the right combination of heat and pressure for the application is critical.

Adavntage of heat stakes :

• similar and sissimilar materials may be joined:metal to metal,plastic to palstic,metal to plastioc.
• Accurate control operating within a small process window.
• local heating resuliting in no damage to surrounding materials.
• Processing of glass-filled materials.
• No machanical vibration.
• Many heat stakes possible throught custom design tool.

2 WAY AND 4 WAY LOCATORS :

In any kind of assembly before fixing the part to the meting part we need to fix the postion of part to mating part we need to fix the position of the part with respect to the mating part.in these case,we need to follow some engineering principles.In this projectwe going to follow 3-2-1 principles.Any part which has to be fixied during welding or machining process has to fixed is having 12degree of freedom.

• Translation movement along X Axis
• Translation movement along Y Axis
• Translation movement along Z Axis
• Rotational movement along X Axis
• Rotational movement along Y Axis
• Rotational movement along Z Axis

PLASTIC PART DESIGN GOALS FOR A SUCCESSFUL PRODUCTION PROCESS.

• Material consideration
• Radius
• Wall Thickness
• Gate location
• Draft
• Inclusion of ribs
• Mold shrinkage
• Special features.

Design of 4 way locators

4-way means you prevent movement at 2axis (+X,-X,+Y,-Y) on the plane .generally you have cylindrical pin on the fixture and circular hole at workpiece part ,2-way means you prevent movement only at 1 axis on the plane.And generally you have cylindrical pin on the fixture and slot hole at workpiece part.

PROCUDURE :

• Extract class A surfce and extrapolate and trim it
• Create tooling direction

• To create 4-way locator
• Sketch 4 way locator and then create pad
• Insert draft 0.5 deg and take base as neutral face
• After draft insert chamber and then fillet it
• Copy 4-way locator and past it use translate and create 2nd 4-way locator

• To create 2-way locator
• Sketch 2 way locator and then create pad
• Insert draft 0.5 deg and take base as neutral face
• After draft insert chamber and then fillet it

• Take boundary by using class A surface
• By using parallel curve offset to 15mm
• using point and repetation insert point in line

• create sketch for heat stake and pad it
• copy paste the pad and translate take first point as a parent and select second point

• To create counter hole for 4-way ,2-way and heat stakes .insert sketch and pad it
• By using boolean operation remove make a hole

DRAFT ANALYSIS :

TREE STRUCTURE :