Week 9 - Project 1 - Door Applique Design with Engineering Features
AIM :
To create a solid body of a given door applique and to create the locators and heat stakes on it as per design standards.
INTRODUCTION:
Heat staking
Heat staking is plused-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 thermoplastic to a part of a dissimilar material, weather it can be 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 components 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 produre the head,locking the component in a place . The progressive melting of the plastic under continous pressure forms the head . When staking, the right combination of heat and pressure for the applications is critical.
Advantages of heat stakes:
1. Similar and dissimilar materials may be joined metal to metal, plastic to plastic, metal to plastic.
2. Accurate control operating within a small process window.
3. Local heating resulting in no damage to surrounding materials.
4. Processing of glass-filled materials.
5. No mechanical vibration.
6. many heat-stake shapes possible through custome designed tools.
2 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 3-2-1 principle. Any part which has to be fixed during welding or machining process has to fixed during welding or machining process has to be fixed is having 12 degrees of freedom.
1. Translation movement along x axis
2. Translation movement along y axis
3. Translation movement along z axis
4. Rotational movement along x axis
5. Rotational movement along y axis
6. Rotational movement along z axis
PROCEDURE:
1) input Given:
2)Tooling Axis
Tooling axis is nothing but the direction in which the core and cavity opens and closes. Design engineer works is to analyse the class A surface and find out the best possible tooling direction keeping in mind all the draft angle is with repect to the tooling axis so that the component can be easily ejected from the moulds.
3) A Class surface
In automotive design , a class A surface is any of a set of freefrom surfaces of high efficiency and quality. Although , strictly, it is nothing more than saying the surfaces have curvature and tangency alignment - to ideal asthetical reflection quality , many people interpret class A sufaces to have G2 (or event G3) curvature continuity to one another. Class A surface modellers are also called digital sculptors in the industry. industrial designers develop their design styling through the A-surface, the physical surface the end user can feel touch, see etc.
4) B class surface creation
Represent internal and functional surfaces. This cluster exemplary includes derived surfaces created by offset operations from class A surfaces to define the tickness of material. in the file it is important to link class B surfaces geometically to enable an adaptation to class A surfraces automatically in case styling change.
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 surface A surface cointains.
5) C class surface creation
Class C surface is swept along the bondary of the class A at an angle perependicular to the Class A surface with respect to the tooling axis direction with a draft angle of 3 degree.
6) Joining class A, B and C surfaces to get a closed surfaces
After finishing all the 3 surfaces, join the class A and class C surface together using the join command. Now the joined surfaces are then trimmed with class B surface to form a closed surface.
7) Draft Analysis
The draft analysis command anables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color range s identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
Draft angles are very important in thermofroming product design. if the product id formed onto a female or negative mold, it shrinks away from the mold side walls. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles.
8) Creating 2 and 4 way locators and heat stakes:
4-way locators mean you prevent movement at 2 axis (+X,-X, +Y and -y) On the plane . genarally you have cylinderical pin on the fixture and circular hole at work piece part.
2-Way locators mean you prevent movement only at 1 axis on the plane.
while creating the locators we need to follow the design rules to create the ribs in order to avoid the sink marks on the components.
Heat staking is plused-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.
Once done with the design of locators and the heat stakes we need to design the conter holes in the mating parts with standard clearances as shown in picture below.
CONCLUSION:
1. Thus the door applique id developed by using given class A surface.
2. 2 and 4 Way locators has been designed in order to fix the position of the applique with the mating door panel and designed the heat stakes which used to fix the component with the mating panel by melting.
feature tree
