Week 9 - Project 1 - Door Applique Design with Engineering Features
OBJECTIVE:
To create the Door Applique Plastic component through the given Class-A surface and the Heat Stakes and the locators considering the design rules. Also to find the tooling direction of the given Class-A surface.
TOOLING AXIS
The tooling axis is found using the trial by error method. A line is drawn along the Y-direction and the draft analysis is performed.
DRAFT ANALYSIS
Draft analysis is a method used in design to check whether the component created in CAD is manufacturable based on the draft condition applied. The main reason behind the draft analysis is the part manufactured should be easily removed from the mold. It also gives an idea of the draft angle from the tooling direction. here we are giving a tooling direction in order to eject the component easily from the tool. The ideal draft angle given in automotive industries for plastic components is 3 degrees.
The given Class-A surface is cleared in the draft analysis.
CREATION OF CLASS-B SURFACE
The B surface is created by extracting the Class-A surface by 2.5mm. For multiple surfaces trim option is used.
CREATION OF CLASS-C SURFACE
The C surface is created by using the sweep option with draft direction. The tooling axis is used as the draft direction.
CREATION OF SOLID PART
Once the Class B and C surfaces are created, then they are converted into a solid by closed surface or thicken option.
DESIGN OF 4-WAY LOCATORS
Two 4-Way locators are created at the top left and right corners. The design rules followed for creating the ribs are followed here as well.
The draft is given along the tooling axis.
DESIGN OF 2-WAY LOCATORS
A 2-Way locator is created in the same way as the 4-Way locator.
DESIGN OF HEAT STAKES FOR ATTACHMENT
The total number of heat stakes needed is decided and points are created. The design rules followed in creating screw boss are followed here as well. Initially, a single heat stake is designed. Then, it is translated to where ever needed using the Translation option.
DRAFT ANALYSIS ON DOOR APPLIQUE
Once the 4-Way locators, 2-Way locator, and the heat stakes are attached to the applique, then the draft analysis is performed on the part.
FINAL ASSEMBLY
After completing the attachments on the applique, the hole is created on the fixing body with the clearance value of 0.1mm for Locators and 0.5mm for Heat stakes.
Therefore, the door applique is designed with the necessary attachment feature according to the 3-2-1 principle.