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

Create the Door Applique Plastic component through the given Class-A surface.

Given CLASS A SUREFACE of door applique and counterpart

• Below images are Position sketches of 4 WAY LOCATOR, 2 WAY LOCATOR and HEAT STAKE are Iso-constrained

• Tree Structure having geometrical set as "INPUTS"

• Report
• A detailed report should be done explaining the draft analysis and the tooling axis creation.
• An explanation should be given on the way of creating the tooling axis particularly the Bisecting method.

Draft analysis done on the given CLASS A SURFACE and TOOLING AXIS created along Y direction and through its midpoint ,perpendicular to the Class A Surface

Class A surface shown in various iterations and compass inversion to clear the component on the other side

Below image shows The DOOR APPLIQUE draft analysis cleared

• CREATION OF 4 WAY LOCATOR,2 WAY LOCATOR and Design rules to be followed are as follows

1. Create 4 way locator sketch in position sketch and have to be Iso-constrained
2. PAD the sketch after creating a body in the tree structure
3. Draft angle of 0.5 deg is given on its sides,neutral element being its lower face
4. Chamfer angle 45 deg on its edges
5. Minimum Edge fillet given as 0.3 deg
6. using TRANSLATE command another locator can be positioned on the door applique elsewhere as required by the designer.
7. Cutout to be made on the counterpart so sketch created ensuring minimum gap between 4 way locator and counterpart
8. PAD the cutout sketch and select the counterpart,use REMOVE option.Cutout made
9. Minimum gap for a locator should be 0.05 mm per side and 0.1 per side is also acceptable

• CREATION OF Heat stakes and Design rules to be followed are as follows

• Heat stake used to seal the components to the other by heating the component while its pressed againt each other

1. Create a sketch in position sketch for heat stake and have to be Iso-constrained
2. PAD the sketch after creating a body in the tree structure
3. Minimum Edge fillet given as 0.5 deg
4. using Point to Point option on TRANSLATE command another heat stake can be positioned on the door applique elsewhere as required by the designer.
5. Point 1 should be the point of parent heat stake and Point 2 should be the desired location of the heat stake
6. Cutout to be made on the counterpart so sketch created ensuring minimum gap between heat stake and counterpart
7. PAD the cutout sketch and select the counterpart,use REMOVE option.Cutout made
8. Heat stake as per design rules should be second in operation so has to be smaller in length compared to our locator in the above design
9. The clearance gap between the heat stake and counterpart should be 0.05 per side and 0.1 per side is also acceptable

Below images show that the 4 way locators, 2 way locator and Heat stakes created following design rules.

Draft analysis done on the counterpart and the Door applique component

Draft analysis angle given as 3 deg

Door applique draft analysis cleared and shown in various iterations in the below image

Counterpart draft analysis cleared and shown in various iterations in the below image

• Screenshots of the completed design in various orientations (Isometric, Front, Side, and Top View)

NOTE:The CATpart is submitted as an attachment below in ZIP file format

THANKYOU.