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

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

Aim- Create the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique. Consider the thickness of the part to be 2.5 mm.

Objective :

• Create the Tooling axis by using the bisecting method.
• Design the class-B and class-C surfaces and join them.
• Create the solid feature by surfaces we create.
• Design the required Heat Stakes & Locators and analysis them.
• Design the required Dog House and analysis them.
• Perform the Draft analysis for the final component.

Theory :

Tooling Axis :

Class-A surface is first analyzed to create the tooling axis or tooling direction that molds pull apart in injection molding. Tooling direction is important for plastic product design as it decides the direction for mold separation.

Step followed for the creation of tooling axis :

• Reference point is first created on the extracted surface.
• New axis system is deployed to plot clearance lines.
• The X-direction and Y-direction along the class-A were used to create the tooling axis.
• Graphic properties of the tooling axis were changed before publishing.

Draft Analysis :

The Draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees. A functional part for injection molding has to have Drafts facing both cavity and core sides to reduce the risk of damage to the parts and ensure ejection. And also important is to overcome the vacuum forces by letting air in between the metal to the plastic for the part to release properly. Adding maintaining a decent cosmetic finish.

The draft should be a part of the design for manufacturing and the plastic product Designer should be aware of its need at the outset of the design process. This allows considerations for design requirement's to be taken into account.

Nominal values for Draft angle :

• 3 Degrees is the nominal Draft angle.
• A minimum of 1.5 Degrees can be manufactured with special tools. But it will increase the manufacturing cost.

FEATURE TREE:-

TOOLING AXIS:-

It is nothing but the direction in which the mold opens and closes the draft angle needed to be provided by considering this tooling axis.

We can create a tooling axis by using the bisecting method.

Create the Dog House for the Door Trim-

"C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• The height of ( B ) should be between 3.0 – 6.0 mm

Create the Heat Stakes & Locators for the Door Trim-

Guidelines for creating locator

• Min draft: 0.5mm per side
• Max fillet radius: 0.25mm
• Rib height: less than 5* nominal wall thickness
• Rib should be spaced with a height to width ratio: 3:1 or 2:1

HEAT STAKES

• Thermal staking is an assembly method that uses the controlled melting and reforming of a plastic stud or boss to capture or lock another plastic or metal component of an assembly in place.
• Heat stakes is used to arrest the degree of freedom of locators by 3-2-1 principle in automotive tooling design.

Guidelines for creating heat stakes

• Min 15mm gap between heat stakes
• Max fillet radius: 0.25mm
• Max clearance with the counter clearance should be 0.5mm.

Conclusion :

Hence the Rib for the drill handle considering the design rules for Door Trim-Dog House creation & also done Draft analysis @ 3 Dgr its look fine most of the area but in some point it will getting fail show in img.

END OF REPORT.......