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

AIM :
To create a solid body of a given Door Applique and to create the Locators and Heat Stakes on it as per design standards.

INTRODUCTION :
Heat Staking
Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is tdeform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part iorder to fix the other.
Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such aautomotive, IT and consumer appliances.
In Manufacturing Of thermoplastic components,it is often necessary to join the thermoplastic to a part of a dissimilamaterial,weather it can be a metal,dissimilar material or the other material.Thermal staking is an assembly method that uses thcontrolled melting and reforming of a plasticstud or boss to capture or lock another plastic or a metal component of an assemblin place.The plastic studs protrude through the holes in a component to be locked in a place.the heated thermal tip contacts thtop of the stud ,which melts and fills the volume of the tip cavity to produce the head,locking the component in a place. Thprogressive melting of the plastic under continous pressure forms the head.When Staking,the right combination of heat anpressurefor the applications is critical.
Advantages of Heat Stakes:
Similar and dissimilar materials may be joined: metal to metal, plastic to plastic, metal to plastic.
Accurate control operating within a small process window.
Local heating resulting in no damage to surrounding materials.
Processing of glass-filled materials.
No mechanical vibration.
Many heat-stake shapes possible through custom designed tools.
2 and 4 way locators
In any kind of assembly before fixing the part to the mating part we need to fix the position of the part with respect to the matinpart. In these cases we need to follow some engineering principles. In this project we are going to follow the 3-2-1 Principle. AnPart which has to be fixed during welding or machining process has to be fixed is having 12 degrees 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

PROCEDURE:
1) Input Given :

2)Tooling Axis
Tooling axis is nothing but the direction in which the core and cavity opens and closes. Design engineer works is to analyse thClass A surface and find out the best possible tooling direction keeping in mind all the draft angle is with respect to the toolinaxis so that the component can be easily ejected from the moulds.

3) A Class Surface
In
automotive design, a
class A surface
is any of a set of
freeform surfaces
of high efficiency and quality. Although, strictly, it nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, manpeople interpret class A surfaces to have G2 (or even G3) curvature continuity to one another. Class A surfacing is done usincomputer-aided industrial design
applications. Class A surface modellers are also called "digital sculptors" in the industrIndustrial designers
develop their design styling through the A-Surface, the physical surface the end user can feel, touch, see etc.

4) B Class Surface Creation
Represent internal and/or functional surfaces. This cluster exemplary includes derived surfaces created by offset operations fromclass A surfaces to define the thickness of material. In this file it is important to link class B surfaces geometrically
to enable aadaptation to class A surfaces automatically in case of styling change.
After creating the tooling axis, B surface is to be created which is nothing but the surface parallel to the A surface. B surfaccontains all the fillets and the edges which the A surface contains.

5) C Class Surface Creation
Class C Surface is swept along the boundry of the Class A at an angle perpendicular to the CLASS A surface with respect to thtooling axis direction with a draft angle of 3 degree

6)
Joining CLASS A, B and C Surfaces to get a Closed Surfaces
After finishing all the 3 surfaces, join the class A and class C surface together using the Join command. Now, the joined surfaceare then trimmed with class B surface to form a closed surface.

7) Draft Analysis
The
Draft Analysis
command enables you to detect if the part you
drafted
will be easily removed. This type of
analysis
performed based on color ranges identifying zones on the
analyzed
element where the deviation from the
draft
direction at anpoint, corresponds to specified values.
Draft angles
are very
important
in thermoforming product design. If the product is formed onto a female or negative mold, shrinks away from the mold sidewalls. As a result, true female or negative products can be thermoformed with vertical walhaving zero
draft angles.

8) Creating
2 and 4 way locators and Heat stakes
:
4-way locators
mean you prevent movement at
2
axis (+X, -X, +Y and -Y) on the plane. Generally you have cylindrical pin on thfixture and circular hole at workpiece part.
2-way locators
mean you prevent movement only at 1 axis on the plane.
While creating the locators we need to follow the design rules to create the ribs in order to avoid the sink marks on thcomponents.
Heat Staking
is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is tdeform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part iorder to fix the other.
Once done with the design of locators and the heat stakes we need to design the counter holes in the mating parts with standarclearances as shown in picture below.

CONCLUSION:
Thus the Door Applique id developed by using given Class A surface .
2 and 4 Way locators has been designed in order to fix the position of the applique with the mating door panel and also
designed the heat stakes which used to fix the component with the mating panel by melting.