Week 9 - Project 1 - Door Applique Design with Engineering Features
Door Applique Design
AIM
To Create the Door Applique Plastic component through the given Class-A surface.
To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
Create the Heat Stakes and the locators considering the design rules in door applique.
The first step to create the tooling axis for the door applique in the centre surface of the panel,because of the draft checking
after that create the class b and c surface of the door panel and applique for both surface of the body should create
class b is create with the offset of class A with 2mm and the and also improve the patches of class b
and extrapolate the class b ,because class b should bigger than class a
so that we want to extrapolate the class b
after the close surface is place on the door panel and applique of the plastic should covert into solid
with the help of part work bench. create the new body and defined after that use close surface tool and select the
plastic surface before check the boundary o the surface after that splastic is convert the part .
) A Class Surface
In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality.
Although, strictly, it is nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, many people
interpret class A surfaces to have curvature continuity to one another.
Class A surfacing is done using computeraided industrial design applications. Class A surface modellers are also called "digital sculptors" in the industry.
c.
create the new position sketch with the correct dimension and final check the constain and clsoe the position
now select the pad tools and pad the sketchk of locator . after thatapplied the draft on all side of 0.5 degree
and then applied the chamfer on topof the corner and fillet also applied to 0.25 mm
after the locator is complete use the paste special command make dupilicate of locator and translate the required place
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 deformthe 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
In Manufacturing Of thermoplastic components,it is often necessary to join the thermoplastic to a part of a dissimilar material,weather 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 plasticstud or boss to capture or lock another plastic or a metal component of an assembly inplace.
now we are goint to create the heate stake .draw a sketch on the position sketch and
and pad and draft tool in to 0.5 degree .afterthat use the paste special and copy the baody and placed on the main body
and translate the number of dupilicate and palced where we needed .
after the compelete the door panel and locator and heate stake now move on to door applique and create the hole clearance of locator
An heatskate with sketch and pad the hole and remove from door applique with the help of booleanoperation and figure is showes in down
he 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 continous pressure forms the head.When Staking,the right combination of heat and pressurefor the
applications is critical.
After the applique is check of the draft angle in the partThe Draft Analysis command enables you to detect if the part you drafted will be easily removed.
This type of analysis is performedbased on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point,
corresponds to specified values.
Creating 2 and 4 way locators and Heat stakes :
4-way locators mean you prevent movement at2-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 a pulsed-heat process to join two or more parts out of which one at least is made of plastic.
The process is to deformthe 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 counter holes in the mating parts with standard
clearances as shown in picture below.
2 axis (+X, -X, +Y and -Y) on the plane. Generally you have cylindrical pin on the
fixture and circular hole at workpiece part.
Thus the Door Applique id developed by using given Class A surface .
2 and 4 Way locators has been designed in order to fix the position of the applique with the mating door p
2 and 4 Way locators has been designed in order to fix the position of the applique with the mating door panel
Draft angles are very important in thermoforming product design.
If the product is formed onto a female or negative mold, it shrinks away from the mold sidewalls.
As a result, true female or negative products can be thermoformed with vertical walls having zero draft
angles.