Week 9 - Project 1 - Door Trim Lower with Engineering Features
Door Trim Lower with Engineering Features
Aim: To Create the Door trim lower component through the given Class-A surface.
Objectives:
• Creation of Tooling axis with appropriate draft angle.
• Creation of other surfaces (eg, B and C surfaces) for creating a solid component.
• Perform Draft analysis on Class A surface and Solid model hence created.
Draft
The draft is the amount of taper for moulded or cast parts perpendicular to the parting. line. Draft angles are a design consideration that makes it much easier for a part to release cleanly from a mould. A draft angle is calculated as a degree measurement (or, less often, an inch or millimetre measurement) from the vertical axis of a mould, and it helps account for thermoplastic shrinkage, a practical reality of the injection moulding process for most materials.
Draft angles are generally a requirement of injection moulding design (though there are a select few soft materials, like nylon, that can get away with draft angles of zero). The draft should be a part of the design for manufacture, and all stakeholders and contributors should be aware of its need at the outset of the design process. This includes product designers, design engineers etc and this allows considerations for design requirements to be taken into account. Any draft is always better than no draft.
Importance of Draft:
By accounting for thermoplastic shrinkage during the cooling process, draft angles significantly reduce friction between the finished, cooled part and the side of the mould, Not only does this create a much easier release process, but it also offers several other benefits, depending on the design of the part which is as follows:
• Reduces the chance of damage to the part due to friction during the release.
• Reduces wear and tear and chances of damage to the mould.
• Ensures a uniform, smooth, unscratched finish when required. • Ensures the integrity and uniformity of other surface finishes and textures.
• Reduces overall cooling time by lessening or eliminating the need for unconventional ejection setups.
• Most, if not all, of these benefits, offer either direct or indirect overall production cost reductions.
Procedure for creation of Solid model:
The image below shows the given class A surface for which a solid model is to be created.
Tooling Axis creation:
It is defined as the direction in which the mould/core and cavity open. Selection of the direction of the tooling axis depends on the ease at which components can be easily ejected.
By analysing the component the most easily ejectable direction is somewhere close to the Z direction,(might be inclined to it) so we have create intersection on the XY plane of Axis System) to create a bisecting line considering the 2 faces which might be difficult to be tooled.
In the Intersection on the XY plane , line is drawn with a suitable Points to the both
side face so that with the resultant tooling axis the side face is cleared.
Then resultant tooling axis is created using the bisecting method.
Draft analysis :-
Draft analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values. Minimum draft angle is considered as 3 degree.
Same steps are followed to get the draft analysis of the solid part as in Class A Surface
As we know minimum draft angle for the faces of the plastic component should be 3 degrees. So the value of 3 degrees (considering tolerance) is provided in the Draft analysis colour mode window Inside the colour scale, the GREEN bar shows the draft angle of 3 or above 3 degrees. The blue bar shows below 3 degrees draft angle the other limit being and the RED bar shows the negative draft angle. As shown in the image below all the top faces and side faces of the component are green, while the bottom faces are red. The line of demarcation between the green and red faces is the parting line which divides the core and cavity halves.
The solid model has cleared the draft analysis successfully as shown in the image below.
B-Surface :-
Class B-Surface is extracted from the A-surface and it is offseted at 2.5mm in downward direction.
C-Surface :-
C-Surface connects the class A-Surface and B-Surface. It is created using blends command. Boundry of the class A-Surface is blends to Class B Surface Boundary And then Finally Joined Both Surfaces And Blends .
Final Plastic Body After joined A ,B And C surfaces
Thickness of the component to be 2.5 mm
Final Solid Body :- using close surface
CREATION OF LOCATORS:
To create the locators, I created a sketch on the body. After creating the sketch, I pad it 14 mm in height and thicken it to 1.3mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave 3 mm of chamfer with 45deg of inclination and after I gave a fillet of 0.3mm radius.
4-way locator:
Iso-Constrained and Positioned Sketch
The draft is applied to the sides of the 4 Way Locator. As per the design rule, the ideal draft angle is 0.5 deg.
2-way locator:
CREATION OF HEAT STAKES:
To create the heat stakes, I draw a sketch on the surface. After the creation of the sketch, I pad it to 12mm height and I gave a draft angle of 0.5deg on both sides (inside and outside) and then I gave a fillet with a 0.25mm radius. After creating the heat stake, I created the ribs for supporting purposes. To create the ribs, I draw a sketch and padded it to 8mm in height and 1mm in thickness. After padding the ribs, I drafted 0.5deg in the tooling asix direction and filleted it with a 0.25mm radius. Finally, I union trim the ribs with a heat stake to remove the ribs, which are present inside the heat stakes.
The draft is applied to the sides of the Heat Stake. As per the design rule, the ideal draft angle is 0.5 deg.
The draft is applied to the sides of the Heat Stake Rib. As per the design rule, the ideal draft angle is 0.5 deg
Completed design in various orientations (Isometric, Front, Side, and Top View)
Tree Structure
