Door Applique Design with Engineering Features

AIM :

To create the Door Applique Plastic component through the given Class-A surface.

OBJECTIVE :

• To create the solid models of Door applique AND Door attachment feature.
• To create Tooling axis for the component.
• To create Locators and Heat Stakes for Door applique.
• To perform the Draft Analysis for the component.

HEAT STAKES :

• Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic.
• This process is use to lock another plastic or metal component of an assembly in place.
• The insert is preheated with induction and then pressed into a hole in the plastic part.
• They simplify and reduce the cost of the machinery.
• A Draft of 0.5 degrees per side is the maximum limit.
• These Heat stakes must be lesser in length than the locators.

LOCATORS :

• Locators are components present in plastic design which are used to hold the components in place.
• These are used to arrest the degrees of freedom of a component.
• The types of Locators include 4-Way locator and 2-Way locator.
• A Draft of 0.5 degrees per side is the maximum limit.

CLASS A SURFACE:

• Class A surfaces are those surfaces which are curvature continuous while providing the simplest mathematical representation needed for the desired shape and does not have any undesirable waviness.
• The Class A surface is the used to begin the design of a product.
• All the further intricacies of the component are created based on the Class A surface.

CLASS B SURFACE :

• The Class B surface is created from the Class A surface , keeping the thickness of the component in check.
• The Class B surface resembles an offsetted surface from the Class A.

CLASSS C SURFACE :

• The Class C surface is used to bind the Class A and Class B surface together inorder to form a closed surface.

PROCEDURE :

Creating Tooling Axis

• A point was created on the Class A surface using the location as 0 mm.
• A line was created passing through this point along Y axis to serve as the main tooling axis.

DOOR APPLIQUE

Creating Class B Surface

• The required surfaces were obtained from the Class A surface using Extract command.
• These surfaces were further expanded using Untrim and Extrapolate commands.
• These surfaces were offsetted to a distance of 2.5 mm from the Class A surface.
• The protuding surfaces were trimmed using the Trim command and a proper continuous surface was obtained.
• The necessary fillets were added to the Class B surface.

Creating Class C Surface

• The Class C surface connects the Class A and Class B surface.
• Initially the outline of the Class A surface was obtained using the Boundary command.
• The Curve smooth feature were used to enhance the the obtained surfaces.
• The the Sweep command was used along With draft direction, with a draft angle of 3 degree.
• The Curve smooth feature were used to enhance the the obtained surfaces.
• The required portions were Extrapolated and Trimmed.

Creating Solid Body

• Finally the Class A, B and C surfaces along with the hole were trimmed together to form a closed surface.
• Using the surface created the solid component was obtained using the Close surface feature present in the part workbench.

DOOR ATTACHMENT FEATURE

• The Door attachment feature was created using the Thick surface feature for a thickness of 2.5 mm.

Creating Locators

• A sketch was created on a plane which was created on the point at the middle.
• The sketch was loacted at one end of the Door Applique.
• The sketch consisted of two lines of 15 mm each intersecting at the middle.
• This results in the creation of a 4-way locator.

• This was extruded using the Thicken option in the Pad command , with a thickness of 1.3 mm at neutral fiber which is 40 % of the main wall thickness.
• A Draft of 0.5 degree was provided.
• The required fillets and chamfers were also provided.
• This 4-way locator was copied and translated to the other end of the aplique.

• A sketch was created on a plane which was created on the point at the middle.
• This time the sketch was at the middle of the component.
• The sketch consisted of a single line of 15 mm in length.
• This results in the creation of 2-way locator.
• All the locators were attached to the main body using Boolean operations.

Creating Heat Stakes

• A sketch was created using the same plan as earlier.
• This sketch consist of two circles with an inside diameter of 5 mm and an outside diameter of 7 mm.
• It was extruded to a length less than the locators.

• This extruded part was further used to create multiple heat strakes.
• The outer boundary of the Class A surface was extracted.
• This bounder was offsetted using the parallel curve feature.

• Multiple points were created on this inner curve.
• These points were used to create multiple heat stakes using the one which was created earlier using the Translate feature.
• Thus 5 heat stakes on top and 7 heat stakes at the bottom were created.
• A Draft of 0.5 degree was provided.
• All the heat stakes were attached to the main body using Boolean operations.

Creation of Counterpart Clearances

• Required holes were created on the Door attachment feature surrounding the locators and stakes.
• The clearance gap for the Locator wall must be 0.1 mm.
• The clearance gap for the Heat stakes must be 0.5 mm.
• Sketches were created accordingly and holes were created using the Boolean operations.

Draft Analysis

• The Drafting analysis was performed using the Feature Draft Analysis command.
• The Draft analysis was performed for both the components for a draft angle of 0.49 degree and 0.5 respectively.

MODEL RESULTS :

Feature tree

DOOR APPLIQUE

Front view

Top view

Side view

Isometric view

DOOR ATTACHMENT FEATURE

Front view

Top view

Side view

Isometric view

CONCLUSION :

• The Tooling Axis for the component was created.
• The Door Applique and Door attachment feature was created from the surface geometry.
• Locators and Heat stakes were created at appropriate positions.
• Necessary clearances were provided to the locators and heat stakes.
• The Draft Analysis was performed for both the components.
• Necessary images and files were attached.