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

Q) Create the Door Applique Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model

Ans:

 Objective:

• Draft analysis for given Class A Surface.
• Create B and C Surface with the help of A Surface.
• Need to use close surface feature and have to make solid body.
• Draft analysis for the solid body.
• Need to make locator with the help of 3-2-1 principle
• Heat stakes need to create
• Clearances need to give for door attachment body

Design Consideration:

• Class-A Surface should be aesthetically Smooth
• Class-B Surface should have all the supporting features likes ribs.
• Flashing should not affect aesthetic of class A surface.
• Draft analysis minimum consideration three Degree.
• Two heat stakes gap should be more than or equal 15mm
• Clearances for locator 0.1mm and heat stakes 0.5mm

Process of Draft analysis-Class A surface:

I have check class A surface there is no discontinuity of the surface.

Tooling direction:

Extract class A surface and created one point on the surface. Line direction taken as normal to surface.

Draft analysis done on class A surface.

Class B and C surface creation:

Extract class A surface use untrim option then offset that surface 2.5mm upward.

Again, same operation done and offset also same 2.5mm.

Extrapolate all the surface as per requirement and trim them as per desire requirement.

Now got class B surface.

Class C surface:

Extract class A boundary and used smooth curve to make smooth curve.

 

Use Sweep Operation angle take 6 deg. 

Same way one more surface done .Both C surface extrapolate .then use trim operation make as a one C surface.

Joint Class A and class C surface together, after joint trim done with B surface.

To make solid body use Close surface operation.

Draft analysis also done.

Adding Locator (4 Way and 2 Way) to Door Applique:

3-2-1 Principle:

Operator will use the various clamp to hold the job to withstand cutting forces. Ideally 3-2-1 principle is used to locate the job.

Create one point on the Door attachment surface and crate one plane normal to curve.

Create one sketch for 4-way locator.

Use Pad operation given thickness as 1.3mm. Given draft angle as 0.5°.

Same 4-way locator copy and paste in other side to arrest movement and rotation of the part.

With the help of same plane and same point make 2-way locator.

Assemble all 4-way locator and 2-way locator together with main body the use union trim comment to remove unwanted part surface.

Adding Heat stakes to door applique:

Extract class A surface and offset 2.5mm upward direction.

Again, extract boundary of this surface. Use Parallel curve and take 15mm inside this curve. Same way done by other extract body also.

Use Point and Planes Repetition comment make point on the parallel curve. In two heat stake between gap more than 15mm it should not be less than 15mm.

With same plane and point reference one sketch created. Then use pad comment make solid and given draft angel 0.5°.

   

This body copy and paste with the link. Use translation option Point to point make all heat stake on the body.

Assembly together all the heat stake and union trim done.

Adding Counter part Clearances:

Same sketch taken as reference 4-way locator and make one circle. Created Pad on the surface given draft also.

For locator clearance Gap should be 0.1mm. same way created clearances for other locator also.

Same way create sketch for heat stake also and then use point to point translate and make clearances 0.5mm.

Use Boolean operation and remove unwanted body.

Draft analysis:

Tree Structure: