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

AIM: 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 in the video for the door applique. 

THEORY:

To locate a part to be machined and restrict its motion to accurately do the machining and constraint its motion 3-2-1 principle of location is used.

3-2-1 Principle:

To completely specify the position in space of a three-dimensional

object (such as the cube that’s shown), we refer to six coordinates:

1. Translational position along the X-axis
2. Translational position along the Y-axis
3. Translational position along the Z-axis
4. Rotational position about the X-axis
5. Rotational position about the Y-axis
6. Rotational position about the Z-axis

It is a 3 step process of introducing 3-2-1 point locators in a plane for best support and constraint.

For example, let's say we use 3 points at the bottom of the cube above, which restricts the translational motion along Z(Z+ and Z-), Rotational motion along Y and X(7, 8, 9, 10) This way three degrees of motions have been restricted.

Now we use 2 points from the Y+ the direction of the cube to restricts the Translational motion along with Y(Y+ and Y-), Rotational motion along with Z. This way two degrees of motions are restricted.

Finally to restrict motion along the only remaining degree of freedom that is the Translational motion along the X(X+ and X-) a single point is used along the X+ direction of the cube to restrict all the motion.

PROCEDURE

 Create a Tooling Axis for the Class A surface

• Create a point on the class A surface to move the main tool for component creation on the base surface.
• Mask an axis over the point created with the same directions as the main axis.
• Using Intersect command from Generative Shape design select the YZ plane as the first element and the class A surface as the second element
• After creating the intersecting lines select the Line command and join the vertices which show the most possible draft angle manufacturable.
• Bisect those two lines over the axis point we created

 DRAFT ANALYSIS of Class A surface:

• Draft analysis is applied on class A surface w.r.t tooling axis

Create a CLASS B SURFACE :

Extract and extrapolate the surfaces of class A

Trim the surfaces and offset 

Creating a CLASS C  SURFACE

Extract the boundry of the surface and use smooth curve

Using Sweep with draft direction for 3 degrees Extract all the boundary in required direction with the draft.

Extrapolate and trim the extra surfaces

DOOR APPLIQUE CREATION

Trim all A,B,C surfaces

Use closed surface to convert the surface to solid

DRAFT ANALYSIS of the SOLID part

Draft analysis on the solid part w.r.t tooling axis

Create the 4-way and 2-way Locators.

sketches are extracted using Pad

Draft of o.5 deg is provided and required fillets and champhers are given

Using translate moves the second 4-way locator to the required location as per the 3-2-1 principle.

Similarly, do all the processes for the 2-way locator as well.

Union Trims all the Locators with faces to keep.

Create the Heat Stakes

Using boundary command get the two outer boundaries and using parallel curve get the offset of boundaries inside the body.

using points definition divide and mark points instances accordingly

Create the Holes for Heat stakes and Locators on the door panel body provided.

Pad them just along the door panel's thick surface.

Give a draft of 0.5 degrees and using the remove command cut out of door panel surface.

Tree Structure