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

AIM:

Create the Door Applique Plastic component through the given Class-A surface along with Heat Stakes and the locators considering the design rules for the door applique and at the end perform the Draft analysis on the model.

Methodology:

Create Tooling Axis:

• Create a point on the class A surface using point on surface option.
• Create line with point and direction in Y direction.

• Rename the line as tooling axis.

Create Class B Surface:

• Create a geometrical set, name it as Class B surface and extract all the surfaces of class A separately using extract command.

• Untrim all extracted surfaces and offset it for 2.5mm.
• Extrapolate the offset surfaces and trim them together.

• Fillet the required surface and rename it as class B surface.

Create Class C Surface:

• Create a geometrical set, name it as Class C surface and multiple extract all the edges of the Class A surface.

• Use smooth curve on extracted curve.
• Sweep the smooth curve with draft direction as tooling axis in 5⁰

• Above swept surface is class C surface.
• Trim the class B with class C surface.

Solid Door Applique

• In part design workbench, use close surface on the above trimmed surface to get solid door applique component.

Create Locators

• Create a point on given counterpart surface and create a plane with point and ZX plane.
• Create the sketches with that plane for 4-way locator and 2-way locator.

• In part design workbench, pad the sketches separately.
• Draft the body with tooling axis as pulling direction.
• Use chamfer and fillet on the body.
• Translate the body to required position.
• Union trim the body with solid door applique and select surfaces to keep.

Create Heat Stakes

• Offset the class A surface for 2.5 mm and multiple extract the edges of offset surface.
• Use parallel curve on the extracted edges for 15mm inwards.
• Create reference points for heat stakes using point and plane repetition command and make sure there is adequate distance between locators and the point.

• Combine them in a geometrical set as point reference.
• Create a sketch using the reference points and previously created plane and draw the profile for heat stake.

• In part design workbench, pad the sketch for required height, so that it can surpasses the door applique and counterpart.
• Use thick surface on the counterpart surface for 2mm.
• Draft and fillet the body of the heat stakes.
• Union trim the body with door applique and select surfaces to keep.

Create Counterpart Clearance:

• Create sketch with same points used for creating locators and heat stakes.
• Draw circular profiles on those point with 0.1mm clearance on both sides for locators and 0.5mm clearance for heat stakes and pad for required height.

• Draft the body for 0.5⁰ and tooling axis as pulling direction.
• Remove the bodies with door panel.

Tree Structure:

Draft Analysis:

• Do draft analysis for final component with tooling axis following the general draft analysis procedure.
• To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.

Different Views of the part:

Isometric View:

Front View:

Side View:

Top View:

Conclusion:

Thus, creating the Door Applique Plastic component through the given Class-A surface along with Heat Stakes and the locators considering the design rules for the door applique and performing the Draft analysis on the model are done successfully.