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

Create the Door Applique Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface 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 for the door applique.   

Before we start create the locators and heat stakes we should know about 3-2-1 principle. In which A work-piece free in space can move in an infinite number of directions. For analysis, this motion can be broken down into 12 directional movements or degrees of freedom". All 12 degrees of freedom must be restricted to ensure proper referencing of a work-piece. As shown in Fig 1, the 12 degrees of freedom all relate to the central axis of the work-piece. Notice the 6 axial degrees and 6 radial degrees of freedom. The axial degrees of freedom permit straight-line movement in both directions along the 3-principle axis shown as X, Y & Z. The radial degrees of freedom permit rotational movement, in both clockwise & counter clockwise radial directions around the same three axes. Degrees of Freedom of a Rigid Body Consider the rigid body shown below which is situated in space. It can have 12 degrees of freedom.

2-WAY LOCATORS: A 2-way locating pin restricts motion along 1 axis (or 2 degrees of Freedom), like a round pin in a slot. Likewise, a 4- way pin restricts 4 degrees of freedom along 2 axes. A round locating pin located concentrically in a hole is a common application of a 4-way pin, and helps to further secure the piece.

4-WAY LOCATORS: A 4-way meanyou ptevent movement at 2 axis(+X,-X,+Y,-Y) on the plane. generally, you have cylindrical pin on the surface the fixture and circular hole at workpice part. 

Fristly we create 2&4 why locators so extract the door applique surface of the component then create a point on the surface. here we using positioning sketch, with the help of sketch create a line which is called Tooling Axis.

With the help of sketch apply Extrude feature on the sketch and thicken. after creating a boss applied draft angle on the wall of locators which is not more then 3 degree. but we consider 0.5 degree. and also applied edge fillete value 0.25mm. applying draft (or a taper) to the faces of the part is critical to improving the moldability of part. Without it, parts run the risk of poor cosmetic finishes, and may bend, break, or warp due to molding stresses caused by the plastic cooling. then used boolean operation as union trim with door applique.

Now Creating the heat stakes on the door applique. manufacturing operations currently use many different combinations of attachment methods to keep components together. Common fasteners such as bolts, screws, and rivets can be used to form permanent attachments, but there are attachment methods that don't require secondary hardware. One of those methods is heat staking, which doesn't require additional fasteners. 

Heat staking is the process to attach two separate components together by melting the base plastic material into a shape that will hold the secondary component. It's a permanent attachment method that does not require any additional material such as an adhesive or a solvent to make the permanent bond. The only addition is the heat applied to melt the plastic and a tool to shape the plastic to form the mechanical connection. Heat staking can be done with a precise and rapid operation that also offers repeatable results every cycle. Manufacturing machine can be developed to complete multiple heat staking operations at once to decrease cycle time. The stakes don't have to be parallel which makes the design options limitless. Heat staking is a great option that is comparable in strength and durability to other operations involving secondary fasteners without extra cost. These connections can also resist corrosion in harsh environments.

REASONS FOR HEAT STAKING:

1.Mutiple staking shapes for different benefits.

2.Excellent durability.

3.No extra materials are needed.

4.Increased efficiency.

5.Easy Maintenance.

Using the same sketch create a circle and use positioned sketch which is Iso-Constrained. then aplied pad command with draft angle 0.5. then trim with door applique base surface. 

In the end create a holes on the counter part with the help of boolean operation as remove command and check the analysis of draft angle.