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

OBJECTIVES:

To create a door applique design from the given class A surface and to create engineering Features to fit the component in the main surface.

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 to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order 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 as automotive, IT and consumer appliances. In Manufacturing Of thermoplastic components, it is often necessary to join the thermoplastic to a part of a dissimilar material, whether it can be a metal, dissimilar material or the other material. Thermal staking is an assembly method that uses the controlled melting and reforming of a plastic stud or boss to capture or lock another plastic or a metal component of an assembly in place. The plastic studs protrude through the holes in a component to be locked in a place. The heated thermal tip contacts the top of the stud, which melts and fills the volume of the tip cavity to produce the head, locking the component in a place. The progressive melting of the plastic under continuous pressure forms the head.

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 WAY 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 mating part. In these cases, we need to follow some engineering principles. In this project we are going to follow the 3-2-1 Principle. Any Part 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:

First import the Class A Surface of Door Applique model in CATIA V5.

Check the connectivity of Class A Surface using boundary option. Ensure that there is no gap between the two surfaces.

TOOLING AXIS – The tooling direction is used to find the direction in which the part is ejected out of the mold. The draft on the part should be positive in order to manufacture the part easily. The draft angle should be positive with respect to the tooling direction. Here the Y direction gives the proper view for the tooling axis. Now, we know the know Y direction is from where the tooling axis is going to lie but we don’t know the direction for the axis. So, the base is extracted and the point is created at the center of the surface. Then at this point, a line or axis is created in the Y direction.

After creating the tooling axis, B surface is to be created which is nothing but the surface parallel to the A surface. B surface contains all the fillets and the edges which the A surface contains.

first we need to extract the surfaces from the a surface and then offset it and then trim it

now applying fillets to it.

now extract the boundary of class a surface of door applique and sweep it with respect to the draft direction that is tooling axis then add the class A and class surface

now trim the class a class c with the class B surface to get the closed surface

now making it a close body

now performing the draft analysis on this closed surface

now making the 4 way locators on the door applique first we have to draw the sketch and then padded it and then applying draft on it to and then applying fillets and chamfer to it and finally assemble it with main component

now copying the same locator and pasting it by using result with the link option and then translating to the right corner of door applique

now drawing the sketch for the 2 way locator

now applying draft to the 2 way locator and padding it and applying fillets and chamfer to it and assemble it to the main component

now drawing the sketch for the heat steakes

now pad the sketch and assemble it to the main component

now copy it and paste along result with the link and then translate it and doing same for all heat stakes.

now creating clearances for the 2 way 4 way locator and heat stakes. firstly we have to draw the sketch for it. and then pad it and remove it from the part and insure that distance from all the sides of locator is same. And the draft the inner side of the holes.

and copy the same body and translate it to the other sides of heat stakes. and them remove it from the body so it will make a hole

final product: