Week 9 - Project 1 - Door Trim Lower with Engineering Features
AIM
Create the component through the given Class-A surface. 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
CLASS A SURFACE
In automotive design, a class A surface is any of a set of free form surfaces of high efficiency and quality. It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.
CREATING THE CLASS A SURFACE
We have been given the Class-A surface and the first thing to do is to make sure that the given surface has no gap in between them. We can check it visually and also with help of Join or boundary commands.
TOOLING AXIS
TOOLING AXIS is created by bisecting the axis created on two intersections .
the best tooling direction for the class-A surface is along y-axis direction.
Flat surface on the center part is extracted for creating the tooling axis in y direction
Then created a with the point and direction along y axis.
TOOLING AXIS of the part is created
DRAFT ANGLE
When developing parts for plastic injection molding, applying a draft (or a taper) to the faces of the part is critical to improving the moldability of your part. Without it, parts run the risk of poor cosmetic finishes and may bend, break, or warp due to molding stresses caused by plastic cooling. Equally important, an absence of draft may prevent parts from ejecting from the mold, damaging not only the parts but possibly the mold itself—a costly and time-consuming detour.
DRAFT ANALYSIS OF CLASS A SURFACE
Change the view to material mode for draft anlysis
draft analysis is done using featured draft analysis tool
Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar
the surface is showing green colour so that the surface clears the minimum draft angle of 3 degree
By using the analyses under the running pointwe can check draft angle on the individual faces. It shows how much draft on specific points when we move the cursor point.
Green colour - above 3 degree positive draft
Red colour -between 3 and 0
blue colour- below 0 degree
CLASS B SURFACE
Class-B surface means the thickness of a part it is not visible and is inside part. In other words, the Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.The Class B finish is a quality finish with only minimal imperfections. A Class B finish is the most common finish for exterior surfaces. It is normally specified on surfaces such as external covers, panels, and parts that are fairly prominent.
B SURFACE is created by Offseting the class-A surface to 3mm inward direction.
patches are created while offsetting the surface. Rework on the patches using the features like extract, multi-extract, sweep, multi-section surfaces, extrapolate.
the boundary command is used to identify and highlight the patches
CLASS B SURFACE IS CREATED
The surface that joins class-A and class-B surfaces are class-C surfaces. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembledThe Class C finish allows more imperfections than Class A or B. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic finish.
The method used for class c surface is sweep feature
Since it is a complex class-A surface, we cannot create the class-A boundary curve and sweep in a single stretch .
small sections are created using multi-extract command and then create sweep of 90 degree with draft angle .
In fillet area and comples area's multi section's surface is used.
SOLID SURFACE
CLASS A and CLASS C is JOIN together
CLASS B is trimmed with CLASS A AND C
SOLID SURFACE FORMED
TREE STRUCTURE
PART BODY
Close Surface feature usedto make a solid body from the surface
HEAT STAKES AND LOCATOR
LOCATOR
4 WAY LOCATOR.
4-way mean you prevent movement at 2 axes (+X, -X, +Y and -Y) on the plane. Generally, you have cylindrical pin on the fixture and circular hole at workpiece part
the face is extraced and point is created for locator
sketch is drawn according to the dimension
using par locator is created
provided draft
entry chamfer is created
provided fillet
4 way locator is created
a copy of locator is created to form 2nd locator
use translate to mave the locator to position
2nd 4 way locator created
2 WAY LOCATOR
A 2-way locating pin restricts motion along 1 axis (or 2 degrees of Freedom), like a round pin in a slot. Likewise, a 4-way pin restricts 4 degrees of freedom along 2 axes. A round locating pin located concentrically in a hole is a common application of a 4-way pin, and helps to further secure the piece
pad used for creating the locator
provided draft
provided entry chamfer
provided fillet
Trimmed with main componenet
2 way locator created
HEAT STAKES
Manufacturing operations currently use many different combinations of attachment methods to keep components together. Common fasteners such as bolts, screws, and rivets can be used to form permanent attachments, but there are attachment methods that don’t require secondary hardware. One of those methods is heat staking, which doesn’t require additional fasteners.
Heat staking is the process to attach two separate components together by melting the base plastic material into a shape that will hold the secondary component. It’s a permanent attachment method that does not require any additional material such as an adhesive or a solvent to make the permanent bond. The only addition is the heat applied to melt the plastic and a tool to shape the plastic to form the mechanical connection.
Heat staking can be done with a precise and rapid operation that also offers repeatable results every cycle. Manufacturing machine can be developed to complete multiple heat staking operations at once to decrease cycle time. The stakes don’t have to be parallel which makes the design options limitless.
Heat staking is a great option that is comparable in strength and durability to other operations involving secondary fasteners without extra cost. These connections can also resist corrosion in harsh environments.
plane is created in one of the points provided for creating heat stakes
sketch is created forthe heat stake
provided inside and outside draft
provied fillet
the heat stake is created
the copy of heat stake is created and translate to all 16 points
trimmed with main body
COMPONENT IS CREATED
DRAFT ANALYSISOF COMPONENT
Change the view to material mode for draft anlysis
draft analysis is done using featured draft analysis tool
Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar
the surface is showing green colour so that the surface clears the minimum draft angle of 3 degree
By using the analyses under the running pointwe can check draft angle on the individual faces. It shows how much draft on specific points when we move the cursor point.
the main body clear the 3 degree draft
the heat stakes and locator clearthe .5 draft angle
Green colour - above 3 degree positive draft
Red colour -between 3 and 0
blue colour- below 0 degree
CONCLUSION
- TOOLING AXIS for the CLASS A SURFACE is created
- CLASS B AND CLASS C surfaceis created from CLASS A surface
- SURFACE MODEL is created using CLASS A,B & C surface
- SOLID BODY is created from SURFACE MODEL using close surface
- 4 WAY LOCATORS AND TWO WAY LOCATORS are created considering the design rules
- HEAT STAKES CREATED in theprovided points
- DRAFT ANALYSIS is done on CLASS A SURFACE and SOLID BODY
- Publications: Use the publication option published the following
- Tooling Axis
- Class A, B, and C surface
- SURFACE MODEL
- SOLID BODY