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

AIM:

To create Plastic design and attach the Engineering features and generate the Draft Analysis for the given Door Applique Class A model.

DOOR APPLIQUE

DOOR ATTACHMENT SURFACE

PROCEDURE:

1.Check for any openings in the given model Door Applique by using BOUNDARY. In BOUNDARY > select edges - select the surface to create the boundary at the openings.

2.Create a point at the center of the surface by using Point Definition by : Point Type - on surface ,Surface - select the surface and Distance - 0

3.By using the Line Definition option create a line in Y direction by : Line Type - Point-Direction, Point - select the point and Direction - Y which will be the Main Tooling Axis(Yellow).

4.Do the draft analysis on Class A surface.

CREATING B-SURFACE FOR DOOR APPLIQUE:

5.Extract the Class A surfaces by selecting the surface to extract and Untrim the surfaces by selecting the surfaces which are required and offset the untrimmed surfaces by selecting the surfaces to offset to a distance of 2.5mm and then trim the surfaces.

6.Fillet the surface with a radius and extrapolate the surface.

CREATING C-SURFACE FOR DOOR APPLIQUE:

7.Extract the Boundary of Class A by Extract option and Using Sweep option create the Class C surface.

8.Smooth curve the extracted boundary and then in Sweep option : Type - With draft direction , Guide Curve - Boundary and Draft direction - Tooling axis and angle as 3 degrees.

9.Create the C surface for 2 boundaries separately.

10.After creating the C surface,join the Class A and Class C surface by Join option and then trim it with the B surface.

11.In Part Design,fill the surface body with the solid using Close surface.

ADDING LOCATORS(4 WAYand 2 WAY) TO DOOR APPLIQUE:

12.Create a point at the center of the surface of Door Attachment by Point Definition.

13.Create a plane on the surface at the center by Plane Definition with reference to the Point which was created and then create a sketch of a 4 way locator on the plane.

14.Pad the Sketch in Part Design, in Pad : Type - to surface , Limit - select the surface as limit and Profile - Sketch and in Pad tick mark the “Thick” option and then click the more option and select the Neutral fibre and the thickness 1 should be 40% of the main wall thickness.

15.Draft the faces of the padded area by Faces to draft - select the faces to draft , Neutral element selection - select the base surface and pulling direction - Tooling axis.

16.After drafting the faces,chamfer the edges at the top and Objects to chamfer - select the edges , Mode - Length/Angle.

17.Fillet the edges and faces.

18.Copy the Part body of the 4 way Locator and Paste it Special with reference link and then Translate it to the other side by coordinates by Translate option : Vector Definition - Coordinates.

19.Now create a 2 way Locator at below the center by creating a sketch and do the same process of Padding,Drafting,Chamfering and Filleting.

20.By Boolean operation,Unitrim the Locators with the Solid body of Door Applique by selecting the faces to keep.

ADDING HEAT STAKES TO DOOR APPLIQUE:

21.Offset the Class A surface to 2.5mm and extract the boundaries of the offsetted surface.

22.Parallel Curve the extracted boundaries by Parallel Curve Definition : Curve - extracted boundary, Support - surface , Constant - distance.

23.Give the Points Repetition to the Parallel curves by Points and Planes Repetition by : Curve - Parallel curve, Parameters - Instances and Instances - no of points.NO Heat stakes should present nearer to Locators.

24.Now create a sketch on the point created on a Parallel curve.Draw the circles with diameters of 5mm and 7mm and in Part Design,Pad it : Type - to surface , Limit - select the Class A surface.

25.Copy the Part body of the Heat Stake and Paste it Special with reference link and then Replicate to the points which are created by Translate option : Vector Definition - Point - Point.Translate the part body of Heat Stake to the other point which was copied by selecting the start point and endpoint.

26.By Boolean operation,Assemble all the Heat stakes part bodies in a single body and then Unitrim the Heat Stakes with the Solid body of Door Applique by selecting the faces to keep.The distance between the tip surface of locator and Door Attachment surface should be equal for all locators.Also the height of Heat stake should be smaller than the Locators.

THICKEN THE DOOR ATTACHMENT SURFACE AND CREATING CLEARANCES FOR LOCATORS AND HEAT STAKES

27.Thicken the Door Attachment surface by Thicken option in Part Design by selecting the surface to thicken to 2.5mm.

28.Now from the Locators sketch,copy the sketch into a new geometrical set and then draw a circle of 15mm and make the old sketch as construction lines where making the clearance for Locators.

29.Pad the circle to an offset distance below the Door Attachment surface and draft the surface to 0.5 degrees.

30.By Boolean operation,remove the Pad from the Thicken surface.So the clearance gap between the Locator wall and clearance wall should be 0.1mm to lock the motion.

31.Do the same process for remaining Locators and Heat stakes by creating the Clearance gaps where the Clearance gap for Heat Stake should be 0.5mm.

32.Finally do the Draft Analysis for the final component

RESULT:

Create the Plastic design and attached the Engineering features and generated the Draft Analysis for the given Door Applique Class A model.