Challenge

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

DDinesh K17 Feb 2021

DOOR APPLIQUE

The applique is a decorative member which is fastened to a vehicle surface (e.g., to a door frame structure adjacent a pillar) in order to add styling and/or to functionally cover unsightly portions of the vehicle.

INPUT :

Class A and Class B Surface of a Door Applique was given.

PROCESS TO BE CARRIED :

Locators and Heat stakes should be designed on the B Surface with the guidelines. Also all the degrees of freedom should be arrested having only one degree of freedom for the Door Applique.

PROCEDURE :

Initially the Class A Surface of the applique was thickened to 2.5mm. So that the B Surface can be extracted now from the thickened solid.

Now all the process going to be carried in the B Surface.

Initial process is to create a point on the middle of the surface and then create a plane using the point and ZX Plane as reference. Name the plane as plane 1.

TOOLING AXIS

Create the Tooling axis by drawing a line using point and direction using the point created on the surface and choose the direction as Normal to Surface option. Publish the Tooling axis.

FOUR-WAY LOCATOR

A sketch is created for the four way locator and dimensioned appropriately.

The sketch is extruded using pad command and thickened for 1.3mm using Neutral Fibre. The direction should be towards the Door Applique as it must be extruded to the other side of the Applique Also to be considered that the extrude must go to the other side of the simplified Surface of the door.

Then the extruded part is drafted for 0.5 degree by having the direction as Tooling axis.

The obtained four way locator is filleted and then the Part is copied and pasted using Paste Special .

The newly pasted fourway locator is translated to the other end of the Door Applique.

The Four-way locators are Union Trimmed with the Door Applique. The faces to be kept are mentioned.

TWO-WAY LOCATOR

A sketch is created and dimensioned for the two way locator and the sketch is extruded using PAD option and by checking the thick surface option, the thickness is mentioned as 1.3mm with checking the Neutral Fibre.

Then the extruded part is drafted for 0.5 degree by having the direction as Tooling axis.

The Two-way locator is trimmed using the Union Trim option by selecting the faces to be kept.

HEAT STAKES

The boundary of the Door applique is extracted using BOUNDARY command, the boundary is offsetted inside the Door Applique by using the Parallel curve option.

Points are created with several instances. By making sure that they dont interfere with the locators.

A sketch for the Heat Stake is created at one of the point by having the point and the plane 1 as reference.

Now the Sketch is extruded using the Pad Command, till both the surfaces.

The Heat Stake is copied and pasted in the main part using the paste special option and translatted to the next point.

By doing the same process the heat stakes are created in all the points.

All the heat stakes are assembled to the car applique.

COUNTER CLEARANCE FOR THE LOCATORS AND HEAT STAKES

Clearance os 0.1mm each side should be made for the locators and the heat stakes to geting the Applique fitted in the Car Door Panel.

First for the Four way locator the sketch is copy pasted again in a new geometrical set and the sketes are converted into construction and the clearance sketch is created and A new body is inserted where the pad command is used to pad the clearance sketch and the body is removed using the Boolean operation. The same is carried for the other Four way locator.

For the two way locator the same process is carried but a new body is inserted seperately for the counter clearance of the two way locator. Finally the pad is removed from the Door Panel using the remove option in the Boolean operation.

In case of heat stakes a hole of extra 1mm in Diameter is sketched having the same point as reference, the hole is extruded using pad command and then the body is removed from the door using the remove option in the Boolean operation.

The extruded body is copied and pasted using paste special option and translated to all the points of the Heat Stakes and the pads are removed from the Door Panel.

FEATURE TREE