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

Aim - To create the Door Trim Lower Plastic component through the given Class-A surface.

DESIGN METHODOLOGY - We have to follow the procedure for designing door trim plastic component which is given below:

1. Tooling Axis - We will create the tooling axis for the given component by below steps:

1. The first step is to ensure that the given surface is a closed surface. This can be fixed by using the join option. For verification use the join tool or the boundary tool.
2. An axis for the tooling direction is decided through visual inspection.
3. The tooling direction in this model will be created paralell to the Y direction. For this a point is inserted at the centre of gravity and a line is created parallel to the X direction through the point.
4. This line will be the tooling axis.

2. Draft Analysis on Class A Surface - We do perform the draft analysis check for class A surface before we make solid and creation of B-side features. Initially we align the compass to the tooling axis and we gave a 2.5deg draft angle for the green colour in the colour bar. If the surface is highlighted in green colour the draft angle is given properly for class A surface. If the class A surface is not highlighted fully in green colour, then we need to coorect the tooling direction.

3. Class B Surface - Now, we create the Class B Surface by taking an offset of 2.5mm in the downward direction but meanwhile an offset it will show a dialog box which states offset have to be created without the subelements. Click on O.K. and then offset will appear with some errors or gap which is shown below:

By enabling Surface Boundaries in Tools<Option<Visualization. All open boundaries will be highlighted in green color as shown above.

Now, remove all the gap by using below tools:

• Multiple extract
• Extrapolate
• Trim
• Edge Fillet
• Multi Section Surface

After using all above tools in right direction we will get the required Class B Surface as shown below:

4. Class C Surface - Now, we will create the class c surface by using Sweep<Line<With reference surface, with respect to Class A Surface as shown below:

5. Class A+C - Now, we will join the Class A & C as shown below:

6. Final Trim - Trim The Class A+C from class B Surface as shown below:

and we will get the complete closed surface as shown below:

As we have enable the surface boundaries option. Due to non-present of green color lines , it states that our object is completely O.K.

7. Closed Body - Now, go to part workbench and use the closed body option which will make our component completely closed.

Note - It will not apply incase of there is open boundary.

8. Create 4 way Locators - To create the locators, I created a sketch on 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.

9. Heat Stakes - To create the heat stakes, I draw a 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.

Finally, we union trim the ribs with a heat stake to remove the ribs, which are present inside the heat stakes.

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

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

10. Draft Analysis On Final Component - Now, we will perforn the draft analysis og the final component as shown below :

Different Views -

Isometric View:

Front View:

Right View:

Top View:

Left View:

Feature Tree-

Conclusion - We have created the door trim lower plastic component through the given Class A Surface.