Week 9 - Project 1 - Door Trim Lower with Engineering Features

DESIGN AND DRAFT ANALYSIS OF DOOR TRIM

Objective:

The objective of the project is to design the DOOR TRIM and to do a draft analysis for it by creating the required tooling direction with the help of bisecting method.

Design Consideraation:

• Class – A surface should be asethetically smooth and good.
• Class – B surface should have all the supporting features like ribs.
• Parting line should coincide with the B surface since flahing couldn’t affect the aesthetic of class – A.
• Class – C surface should also pass the draft analysis.

Procedure for creating the DOOR TRIM:

• First, the given styling surfcae is checked for any irregularities and it found any then its is corrected by using trim, extrpolate, split and join commands.
• The below image shows that the class – A surface is clean and no irregularities present, so let’s move on to the next step.

Creation of tooling direction:

• Considering the ejection from the caavity of the mould after maunfacturing the interior trim must have the nominal 3 – degree draft angle.
• Hence the toooling direction is created by considering the above bfactor and bisecting method is used.
• The base surface of the class – A was extracted and a point at the centre is created and an axis system was inserted to the point with current feature is disabled.
• Then, bisecting lines with the two inclined lines were drawn.
• Now the same procedure is done along the XZ plane but on one side we don’t have inclined lines so the centre point is used to extrude a line along the z direction and gave a measurement of 5 degrees (tentatively).
• With these two lines from sketches 1 and 2, the bisecting line is crated and published as tooling axis (tooling direction).

Creation of class – B surface:

• For creating the class – B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.
• Then all the surface have been extrapolated to get intersections between them.
• Since the thickness of the switch bezel is 2.5mm the B – surface was offset to 2.5mm and the required trim operations must be carriednout.
• Finally, the required corners have been filleted to 12.5mm (15mm – 2.5mm). [15mm – fillet value of the A – surface, 2.5mm – thickness of the component]

Creation of calss – C surface:

• The required outer edges of the A – surface were extracted using multiole extract. Then for avoiding the patches the curve is smoothened using curve smooth option.
• Then by using the sweep command the surface was created with following feature controls,

1. Profile type – Line
2. Subtype – with draft direction
3. Guide curve – smooth curve
4. Draft direction – tooling axis
5. Draft computation mode – square
6. Angle – 3 degree
7. Angle sector – positive downward (1)
8. Length – 20mm

• Then by using extrapolate command the edges wereintersected between the surface corners which eases the trimming operqation.
• Now the required portion of the C – surface were trimmed out.

Creation of closed surface:

• Now the class – A and class – C surfaces were joined together by removing the gaps in between them with help of extrapolation (tangent continuity) and trim surface.
• Then the exact surface of the switch bezel was trimmed from the4 above resulted trim surface with class – B surface.
• Then by defining the part body by using the closed surface coomand in part design, the component’s solid body is created.

Procedure for draft analysis:

• First the class – A surface is checked before creating the class – B & C surface and finally the solid body must be analysed. Both caan be done by following the below procedures.
• By changing the view mode to custom view paramters – material mode then the feaature draaft analysis is enabled.
• Then the compass was activated and place with the tooling axis by dragging the red pointer and then locked it.
• Then by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component’s draft angle.
• The green colour area shows that it satisfies the 3 – dregree draft angle. If not satisfied then by using the running point tool area is measured and then altereed to get a suuccessful draft for the created tooling direction.

Conclusion:

Finally the class – A, B & C surfaces with the tooling direction have been published and the DOOR HANDLE is moved on to the designing of the next operation – the craetion of B side features.