Week 9 - Project 1 - Door Applique Design with Engineering Features
DOOR APPLIQUE DESIGN WITH ENGINEERING FEATURES
OBJECTIVE:
To create Door Applique plastic component through the given Class-A surface with Heat Stakes and the locators considering the design rules.
DOOR APPLIQUE:
Applique is plastic component mounted in the door of a car. To mount this we need locators and heat stakes at the rear side of it. The given class A surface is shown in the figure.
TOOLING AXIS:
Tooling axis is created on the surface of class A by using point direction method. First point is created on Surface and then line created at that point on z direction.
DRAFT ANALYSIS ON CLASS A:
Draft analysis is performed on the class A surface to verify the tooling direction.
CLASS B SURFACE:
Class A surfaces are extracted and untrimmed.
Bottom two surafces are joined together. Then all surfaces are extrapolated and trimmed as shown in the figure.
Edge fillet value is measured on class A surface and the same applied here. Finally this surface is offseted with 2.5 mm.
CLASS C SURFACE CREATION:
Boundary of class A surface is extracted and thid boundary is converted into smooth curve.
This curve is swept at angle of 3 degree with class A surface along tooling axis.
CLOSED BODY:
Class A and class C surfaces are joinned and trimmed with class B surface. Finally this closed surface is coverted into body.
LOCATORS:
Locators are used to arrest the movement of component and fix it properly. Here I have created 3 locators such as 2 four way locators and 1 two way locator. Four way locators are placed both top sides and two way locator placed at bottom centre. So all possible movements are arrested.
FOUR WAY LOCATOR:
Sketch is created on class surface. This sketch is thickened using pad command. Then this body is chamfered and filleted as per design rules.
Given draft of 0.5 degree.
Locator is assembled with Applique boby with remove command. For the other side this locator is translated as shown in the figure. Then this also assembled to the Applique body.
TWO WAY LOCATOR:
Single line is created instead of 2 intersecting line as in the case for 4 way locator. This line thickened,drafted,chamfered and filleted as shown in the figure. Two way locator also assembled to Applique body.
HEAT STAKES:
Heat Staking is a pulsed-heat process to join two plastic parts. So heat stakes are created to join Applique with door panel.
Curve is extracted from all the side. Using parallel curve command curves are offseted as shown in the figure.
Points are created along the curve.
Created a profile for heat stake based on the thickness of the part.
Above sketch is extruded using pad command.
Outer and inner faces are given draft of 0.5 degree.
This heat stake is translated into points along the curve. All heat stakes are assembled together and added to Applique.
Given door panel surface is thickened about 2.5 mm.
Heat stakes and Locators are projected above the door panel. So I have given clearance on the Door panel. It should be maximum of 0.1 mm. So all the holes are created on the door panel within 0.1 mm clearance.
This sketch is padded and drafted. Then removed with door panel.
DRAFT ANALYSIS:
Draft analysis is performed on the final part to ensure whether tooling axis cleared all the sides of part including locators and heat stakes. Here all sides are cleared.
Different views of Door Applique as follows.
FRONT VIEW:
RIGHT SIDE VIEW:
LEFT SIDE VIEW:
TOP VIEW:
ISOMETRIC VIEW:
TREE STRUCTURE:
RESULT:
Door Applique plastic component has been developed from given Class-A surface with Heat Stakes and the locators considering the design rules and draft analysis is performed and results are published.