Week 9 - Project 1 - Door Applique Design with Engineering Features
AIM : To create the Heat Stakes and Locators on the given Door Applique Plastic Component
INTODUCTION
HEAT STAKING :-
- It is the process to join thermoplastic to a part of dissimilar material weather it be Metal, dissimilar plastic or other material.
- also known as Plastic Welding.
Advantage -
- similar or dissimilar material can be join. like- metal to metal, plastic-metal, plastic-plastic
- multiple fastening points.
- Reduced cost of machinery
LOCATORS:-
In the process of fixing of two component/part, we need to fix the part and mating point in such a way that It will be in proper allignment and will not move in other direction.
For that, we use Locators : 2-way Locators, 4-way Locators
3-2-1 Principle - Any part which is going to fix; having 12 degrees of freedom.
- Translational Movement - along X,Y,Z axis
- Rotational Movement - along X,Y,Z axis
Procedure
Given Applique Class-A surface
Class-B surface
- For creating Class-B surface, use steps : Extract - Untrim extract surface - Trim - Offset=2.5mm
- Extrapolate the surface for trimming
Class-B Surface
Tooling Axis
- Create a point on the surface and make a line in Y-direction for our Tooling axis.
Class-C surface
- Unhide class-A surface and make the Extract on it.
- Swap the Extract having angle= 3degree
Class-C surface
- unhide Class-A surface and Join with Class-C surface.
- Trim this joined surface with Class-B surface.
Final Joined surface
- Try to apply boundary ove it, it is showing error; Hence our surface is ready to make it solid body.
Draft Analysis
- Allign the Compass properly
LOCATORS:-
- Create a point and the plane on that point in ZX-axis.
- Start sketching for Locators.
- Sketch for 4-WAY LOCATOR.
- Pad the sketch
4-WAY LOCATOR
- Apply on the faces; Draft angle = 0.5degree
- chamfer=3mm on corner
- Fillet edge Corner=3mm
- Fillet side faces = 0.3mm
- Pad surface - insert in new
- now, Copy the 4-WAY LOCATOR body and paste special it in Main Door RH.
- Translate the Locator
4-WAY LOCATORS
2-WAY LOCATOR:-
- Copy the Locator body and paste special in Driver Door RH
- Create sketch for 2-WAY LOCATOR
- PAD the sketch
- Apply the Draft Angle=0.5
- Apply Chamfer = 3mm on edge
- Fillet=3mm on edge
- Fillet=0.3degree
- now, Union Trim these 4-WAY LOCATOR & 2-WAY LOCATOR with the APPLIQUE BODY.
LOCATORS attached with APPLIQUE
HEAT STAKES:-
- Extract the corners
- Extract upper surface and Apply Parallel Curve at distance=15mm
similarly,
- Apply parallel curve
- Apply points and planes repetation in curves
- create sketch on these points having outer dia=7mm, inner dia=5mm
- Insert a body and PAD
- Copy Heat Stake body and paste special-as a Result link in Driver Door RH.
- TRANSLATE - point to point
Continue the steps for all points, we get
HEAT STAKES
- Insert a new body and Assemble all these Heat Stakes on it.
- Union Trim this HEAT STAKES body with the APPLIQUE body
Counter Part Clearance
- create a sketch having Dia=15.2mm
- PAD the sketch
- Apply Draft Angle=0.5 degree
- Remove the Paded part with the solid part of Door Attachment.
Similarly,
- Copy the sketch of 4-WAY LOCATOR, 2-WAY LOCATOR and paste it in geometrical set inside the Counter part clearance geometrical set.
- Pad the sketches
- Apply Draft angle = 0.5degree
- now, Remove this drafted pad part with Door Attachment solid body.
- Maintain the Clearance = 0.1mm
Clearance for HEAT STAKES
- copy the sketch of Heat stakes in Clearance geometrical set
- delete the inner dia=5mm and increase the outer dia=8mm
- PAD the sketch
- Remove with the Door Attachment body
- Maintain the Clearance = 0.5mm
Similarly
- create sketch (D=8mm) - PAD
- Remove the paded body with the Door Attachment.
- Maintain Clearance = 0.5mm
Final body
Draft Analysis
APPLIQUE
- Allign the Compass properly along the Tooling Axis
- The Applique surface Draft = 3degree
- The LOCATORS Draft angle = 0.5degree in reverse direction.
DOOR ATTACHMENT
DIFFERENT VIEW
