Challenge

Project - Door Applique Design with Engineering Features

AAshif Iqbal24 Jul 2021

DESIGN FEA

TITLE:- DESIGN OF DOOR APPLIQUE

AIM:- TO DESIGN DOOR APPLIQUE WITH ATTACHENT FEATURE

EXPLANATION:-

CREATION OF CLASS A SURFACE:

Join the class A surface to fill the little gap which cannot be seen by naked eyes. Like this we get complete class A surface.
Thicken the door attachment surface to like 2mm.

CREATION OF TOOLING AXIS:-

As we can see that the given surface is flat and don't have some short of projection and depression.So we can simply create a normal line.
Create a point on the class A surface.
Create a line normal to surface passing through that point. We can use point-direction option.

CREATION OF CLASS B SURFACE:-

For class B surface directly offset to thickness of component which is 2.5mm.
Extrapolate it to 1mm so that it will be easy to trim.

CREATION OF CLASS C SURFACE:-

Take a boundary of class A surface.
As lot of irregulatrity where found so We used smooth curve.
Now create sweep using smooth curve and curve and tooling axis a direction with draft of 4deg.
Now join class A surface and class C surface and trim join with class B surface.
Now go to part workbench and change DOOR APPLIQUE SURFACE into close body.
Now we find that there are some area which is open and this error is coming due to class A surface

CLASS A SURFACE IMPROVMENT:-

We find that thier are alomst 4 edge where class A and class C is not meeting.
Extrapolate the 4 edges of class A surface to some extend.
Now go to sweep we create for class C and extend it in another direction also.
Now trim them out and update the join and final trim.
Like this we get close body for our DOOR APPLIQUE of thickness of 2.5mm.

IMPROVED SURFACE

DRAFT ANALYSIS:-

FOR CLASS A

FOR COMPONENT

CREATION OF ATTACHMENT FEATURES:-

1.CREATION OF LOCATORS:-

Locator are feature that asserts the DOF of the component.Thier are two type of locator 4-way locator and 2-way locator and designed on the component using 3-2-1 principle. We will design 3 locators in which we will have two 4-way locator and one 2-way locator which asserts it movement and momentum along XX,YY,ZZ. Using these locator we have asserted 11 DOF of the component out of 12 DOF .

Insert a new geometrical set and name it as locator.
For any design we need sketch so we will create a sketch first for 4 way locator.
Create a point on the surface of Door attachment and insert a plane using that point. Now create a positioned sketch using these points and plane.
We simply create 2 line of 15mm which is perpendicular to each other.

Now go to part workbench and create pad.
Pad should cross both attachment and door applique.

Now give draft to the locator of 0.5deg.

Now add entry chamfer to top and edge fillets to all edges.

Now we union trim the locator with main body by selecting faces to keep.

Similary we create another 4-way locator by copying and using paste special. And translate it to the new position.

Similarly all the process are done for 2-way locator. The only difference for this is that we draw only one line in the sketch.

2. CREATION OF HEAT STAKE:-

Heat stake are bosses which are attached to applique as well as attachment. It is using to fix the 1 DOF which has not been aserted by locators.It is fixed with attachment using plastic welding.

Curve are extracted and shifted using parallel using.
Create same no of points as the no of heat stake is to be created.
We create bosses for heat stake and for that we create sketch of 2 circle of dia 7mm and 5mm.

Now we pad it. Note that It's height should not go beyond the height of locator.
Provide a draft of 0.5deg
Now for all other heat stakes we copy, paste special with link and translate them using points we created initally.
Now union trim them with main body using faces to keep. Do same for all heat stakes.

CREATION OF COUNTERPART:-

Counterpart are used to locate the locators and heat stakes providing them to pass through door attachment.

Insert new geometrical set
We use same sketches for counterpart. copy them and paste it new geomterical set.
Now go inside the sketch and create a circle of 15.2mm which 0.1mm clearance per side.