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

AIM

To study the creation of locator and heat stakes.

OBJECTIVE  

Create the Door Trim Lower 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.

THEORY  

Heat Stakes design :-

                                           figure 1. heat stakes design

• Counter Part Thickness - Will be given as input
• Component Wall Thickness - Will be given as input
• Length of the Rib - 22 mm
• Height of the Ribs - 3 mm to 6 mm
• Inner Diameter of Heat Stake (d) - 5 mm
• Outer Diameter of Heat Stake (d) - 7 mm
• Minimum clearance between heat stake and counterpart - 0.5 mm
• Height of the Heat stake - Depends on the rib height and counter-part thickness
• Minimum fillet of Heat Stakes - 0.25 mm
• Minimum Draft Angle of Heat Stakes - 0.5 degrees

Locator :-

      figure 2. four way locator 

• Height of the locators should be 1 mm (or) 2 mm greater than the heat stakes
• Thickness, fillet and draft angle are of same as rib design rules.
• Ideal Chamfer value - 5 mm x 45 degrees
• Ideal length of the locators - 15 mm

TOOLING AXIS 

Here the tooling axis is created parallel to the Y axis because in this direction we can see the whole surface and surface is not planar. That is create the point on surface and create a line at that point using point and direciton option. Where as direction as XZ plane. Bisecting line method for creating a tooling axis is suitable for symmetric surfaces.

DRAFT ANALYSIS OF CLASS A SURFACE 

                                   figure 3. class A draft analysis 

Here draft analysis carried for class A surface with respect to tooling axis. Here colour code used is a green colour indicating that the draft  is 3 degree or above. The red colour indicates that the draft is 0 degree and the blue colour indicates that the draft is minus value. From draft analysis we can see that green colour is all over the surface and hence it is suitable for further process because it follows optimum draft.

DRAFT ANALYSIS OF A MODEL 

                                  figure 4. door trim draft analysis

Here we need to check the draft of  door trim, locator and heat stakes along tooling axis. First check the for the door trim, we have to set colour for the draft analysis with minimum draft of 3 degrees. Here colour code used is a green colour indicating that the draft  is 3 degree or above. The red colour indicates that the draft is 0 degree and the blue colour indicates that the draft is minus value. From draft analysis we can see that green color over the surface of the door trim. That is the door trim follows optimum draft of 3 degrees.

                                    figure 5. draft analysis with 0.48 degrees

                         figure 7. draft analysis of locator with 0.48 degrees 

                     figure 8. draft analysis of heat stakes with 0.48 degrees.

Next we have to check the draft of locator and heat stakes along tooling axis. Then set the colour code for the draft analysis with minimum draft of 0.48. Here colour code used is a green colour indicating that the draft  is 0.48 degree or above. The red colour indicates that the draft is 0 degree and the blue colour indicates that the draft is minus value.  From draft analysis we can see  that green colour over the surface of the locator and  heat stakes. That is the locator and heat stakes follows optimum draft of 0.48 degrees. 

MODEL VIEWS 

                                                        figure 9. isometric views 

                                     figure 10. front view 

                                             figure 11. right side view 

                                  figure 12. top view 

         figure 13. tree structure 

CONCLUSION

Creation of locator and heat stakes are studied.