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

AIM: Create the Base Bracket 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.

Create the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.

THEORY:

To locate a part to be machined and restrict its motion to accurately do the machining and constraint its motion 3-2-1 principle of location is used.

3-2-1 Principle:

To completely specify the position in space of a three-dimensional

object (such as the cube that’s shown), we refer to six coordinates:

1. Translational position along the X-axis
2. Translational position along the Y-axis
3. Translational position along the Z-axis
4. Rotational position about the X-axis
5. Rotational position about the Y-axis
6. Rotational position about the Z-axis

It is a 3 step process of introducing 3-2-1 point locators in a plane for best support and constraint.

For example, let's say we use 3 points at the bottom of the cube above, which restricts the translational motion along Z(Z+ and Z-), Rotational motion along Y and X(7, 8, 9, 10) This way three degrees of motions have been restricted.

Now we use 2 points from the Y+ the direction of the cube to restricts the Translational motion along with Y(Y+ and Y-), Rotational motion along with Z. This way two degrees of motions are restricted.

Finally to restrict motion along the only remaining degree of freedom that is the Translational motion along the X(X+ and X-) a single point is used along the X+ direction of the cube to restrict all the motion.

Locators:

To Restrict the Degree of freedom of a 3D plastic component Locators used.

There are various types of locators but for this application, we will use the following:

1. 4 Way locator:

A 4-way pin restricts 4 degrees of freedom along 2 axes.

2. 2 Way locator:

A 2-way locating pin restricts motion along 1 axis (or 2 degrees of Freedom).

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. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part to fix the other.

MAIN TREE:

OBJECTIVE 1: Create a Tooling Axis for the Class A surface.

TREE:

PROCEDURE:

• Create a point on the class A surface to move the main tool for component creation on the base surface.
• Mask an axis over the point created with the same directions as the main axis.
• Using Intersect command from Generative Shape design select the YZ plane as the first element and the class A surface as the second element.
• After creating the intersecting lines select the Line command and join the vertices which show the most possible draft angle manufacturable.
• Bisect those two lines over the axis point we created.

OBJECTIVE 2: DRAFT ANALYSIS of Class A surface:

PROCEDURE:

• After Tooling Axis Select the Feature Draft Analysis option from the Insert Option.
• Select the element to analyze.
• Next click on Use the compass to define the new current draft direction option and make it align with the tooling axis by dragging it to the axis.
• If the color appears blue just click the invert option on the right side of the draft direction axis button.

Objective 3: Create a CLASS B SURFACE :

TREE:

Upper Stroke:

Extract the Surface and untrim it.

With point continuity and curvature extrapolate the surface.

Similarly, do the same for lower stroke.

Now trim them and give the edge fillet of 15 mm as found from the untrim parts of the measure.

Now offset the surface to 2.5 mm below.

Objective 4: Creating a CLASS C SURFACE

TREE:

First, use the boundary command to get 2 easy boundaries of the class A surface.

Then using the multiple extract command get the rest of them.

Use curve smooth command to get smoother lines for draft extraction.

Using Sweep with draft direction for 3 degrees Extract all the boundary in required direction with the draft.

Extrapolate all the surfaces and trim with each other.

OBJECTIVE 5: DOOR APPLIQUE CREATION

TREE:

Trim all class A, B, and C surfaces:

Objective 6: DRAFT ANALYSIS of the SOLID part

• Select the element to analyze.
• Next click on Use the compass to define the new current draft direction option and make it align with the tooling axis by dragging it to the axis.

OBJECTIVE 7: Create the 4-way and 2-way Locators.

TREE:

SKETCH:

Using a pad to create a surface with the required height and neutral width of 1 mm.

Give a draft of 0.5degrees.

Give the required fillets and chamfer.

Using translate moves the second 4-way locator to the required location as per the 3-2-1 principle.

Similarly, do all the processes for the 2-way locator as well.

Union Trims all the Locators with faces to keep.

OBJECTIVE 8: Create the Heat Stakes.

TREE:

SKETCH:

Using a pad to create a surface with the required height.

Using boundary command get the two outer boundaries and using parallel curve get the offset of boundaries inside the body.

using points definition divide and mark points instances accordingly

Using the translate command move all the heat stakes to the required position.

Union Trims all the heat stakes with faces to keep.

OBJECTIVE 9: Create the Holes for Heat stakes and Locators on the door panel body provided.

TREE:

SKETCH:

Pad them just along the door panel's thick surface.

Give a draft of 0.5 degrees and using the remove command cut out of door panel surface.

Similarly, copy and translate the parts to required positions and remove them.

Check for Tolerance for both locators and holes.

Objective 10: DRAFT ANALYSIS of the final parts

• Select the element to analyze.
• Next click on Use the compass to define the new current draft direction option and make it align with the tooling axis by dragging it to the axis.

CONCLUSION:

Created the solid part of the given class A surface with the Locators and heat stakes according to the given Door panel surface.