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

OBJECTIVE -

The main objective of this challenge is to create a solid body of ‘Door Trim Lower’ with the help of the closed surface method by using the 'Generative shape design' workbench in CATIA V5 and performing the 'Draft Analysis' on the solid part body of the Door Trim Lower.

OVERVIEW -

Initially, we need to offset the given Door Trim Lower class A surface in the inner direction to the required thickness (here the thickness is 3mm). After that, we need to close the patches on the offset surface of the Door Trim Lower, the patches are formed due to the fillets on the Class A surface. Once all the patches are closed properly join them together to make a proper class B surface and now sweep the boundary of the class A surface to trim with the class B surface to make a closed body. By using the closed body command in the Prat workbench we can get the solid body from the closed surface of the Door Trim Lower. Now, again went back to the surface workbench to perform the 'Draft analysis' for the solid body.

TOOLING AXIS -

To create the tooling axis, I extracted a surface from class A and made a point in the middle of the surface using the print command, and created a line through the x-axis. Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not. If, in the draft, analysis check the surface highlighted with green color on both sides of the surface the tooling axis is in the correct position and direction.

CLASS B SURFACE -

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 2.5 mm, so I offset the class A to 2.5 mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multi-section surfaces command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface.

B SURFACE AFTER REPAIR -

CLASS C SURFACE -

To create the class C surface concerning the boundary of the class A surface, I used the sweep command. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the swiped surfaces until both surfaces got intersected properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the center hole of the bumper.

Now, join both class A and sweep boundary to get the complete class C surface.

Now, unhide the class B and class C surfaces. Check whether all the sides of class B and Class C surfaces are intersecting properly with each other, to get a closed surface by trimming class B and class C surfaces. If the class B and class C sides are not intersected properly, we need to extrapolate the sides of the class B surface which are not intersecting with the class C surface. Now, check class B and class C surface boundaries whether all the sides are intersecting or not with each other. Once the surfaces are intersecting properly trim them together to get a closed surface.

PART BODY:

To create the solid part body from the closed surface, I used the closed surface command in the part workbench.

DRAFT ANALYSIS OF CLOSED PART -

CREATION OF LOCATORS:

To create the locators, I created a sketch of the body. After creating the sketch, I pad it 20mm in height and thicken it to 1.3mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave 3mm of chamfer with 45deg of inclination and after I gave a fillet of 0.3mm radius.

4way locator:

2way locator:

CREATION OF HEAT STAKES:

To create the heat stakes, I sketch on the surface. After the creation of the sketch, I pad it to 15mm 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 6mm in height and 1mm in thickness. After padding the ribs, I drafted 0.5deg in the tooling six 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.

Heat stake sketch:

Heat Stakes support sketch

Now I translated the heat stakes by copy-pasting them in the part body according to the requirement.

Final part body with 4-way and 2-way locators including all the heat stakes with supporting ribs:

DRAFT ANALYSIS FOR PART BODY:

Views -

Feature Tree -