Challenge

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

DOOR APPLIQUE DESIGN WITH ENGINEERING FEATURES

PROCEDURE:

TOOLING AXIS CREATION:

Check for the suitable tooling direction. Usually, a perpendicular axis to large flat surface or hole is considered as a tooling axis.
By inspecting it seems this feature can be cleared in y direction.
Create a point on the Class A surface. Create a line along the Y-axis.

DRAFT ANALYSIS ON CLASS A OF DOOR APPLIQUE

Change to material mode.
Drag the compass and place on to the tooling axis.
Click on the surface. The surface will turn into Green.
It means the angle of the surface is more than 3 degrees with respect to the tooling axis, and it can be cleared in tooling direction.

CLASS B DOOR APPLIQUE

CLASS C DOOR APPLIQUE

FINAL TRIM DOOR APPLIQUE

CLOSE SURFACE

SKETCHES OF B SIDE(ENGINEERING) FEATURES

Four-way Locators:

Sketch for Four-way locators with 7.5mm on each side to arrest the Degrees of Freedom of the component and fix it.
Pad it with thickness of 1.3mm for a depth of 15mm.
Draft each face for 0.5 degrees.
Then give chamfer of 3mm for easy sliding and fillet of 0.25mm to avoid sharp edges.

Two-way Locators:

Sketch for Two-way locators with 7.5mm on each side to arrest the Degrees of Freedom of the component and fix it.
Pad it with thickness of 1.3mm for a depth of 15mm.
Draft each face for 0.5 degrees.
Then give chamfer of 3mm for easy sliding and fillet of 0.25mm to avoid sharp edges.

HEAT STAKES

Extract Boundary of Class A. Use parallel curve tool and get a parallel curve 15mm inside the boundary.
Create points on to the curve for heat stakes. The Minimum distance between heat stakes must be 50mm.

Sketch for heat stakes with two cocentric circles with inner circle diameter of 5mm and outer circle diameter of 6.5mm.
Give 0.5 degree draft. Copy and paste special the body for 12 times(no of points on curve).
Use point to point translation and translate the pasted bodies.

CLEARANCE CUTOUTS

Locators

Sketch for clearance cutouts for Locators.
The clearance for locators must be 0.1mm on each side. So draw a circle of Diameter 15.2mm and pad it . Give Draft of 0.5 degrees and perform boolean operation and remove it from the door attachment body.

Heat Stakes

Sketch for clearance cutouts for Heat stakes.
The clearance for heat stakes must be 0.05mm on each side. So draw a circle of Diameter 6.6mm and pad it .
Give Draft of 0.5 degrees.
Copy and paste special the body for 12 times(no of points on curve).
Use point to point translation and translate the pasted bodies.
Perform boolean operation and remove them from the door attachment body.

DRAFT ANALYSIS

Change to material mode. Drag the compass and place it on the tooling axis.
Select the body. The body will turn green, which means all the features are drafted and clearing in the tooling direction.

ORIENTATION VIEWS

DOOR APPLIQUE

DOOR ATTACHMENT

DOOR APPLIQUE AND DOOR ATTACHMENT

TREE STRUCTURE

CONCLUSION:

Tooling axis is created for the Class A of Door Applique. Draft Analysis is performed.
The Class A of door is applique is used to develop the body.
All the engineering features were created following the design guidelines.
The Class A of Door attachment which is a sheet metal part is used to develop body by using thickness tool.
Clearance cutouts were created on the Door Attachment for Locators and Heat stakes.
The Draft Analysis is done on the Door applique body with engineering features and all the features are found to be manufacturable.

Ship work like this
in your own course.