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

STEP 1- After receiving door trim as input, we check the connectivity of our class A surface using boundary command.

Since their is no gap, we start our 2nd step.

Step 2 - Selection of tooling Axis.

• The direction in which core and cavity open is tooling axis.
• After visualising Class A surface we can say that y-direction will tooling axis direction.
• Now I have checked faces of class A and the lower face is best for tooling axis because when seeing normal view of that face every face/part of class A surface is visible.

• Now i have extracted the face and made a point at cente of this extract.
• From point,I have made a line which is normal to surface.
• This is our tooling axis

Step- 3 Draft analysis for CLASS A -Surface

1. Insert > Analysis > Features draft analysis
2. Make sure it should be in material mode
3. Now go to direction, and click 2nd option.
4. Pick the compass and align it with the tooling Axis and click on the lock .
5. Now click on the class A surface,we will see a green colour surface.
6. So we have performed draft analysis on Class A- Surface and all face are clearing the surface

Step-4 Creation of Class-B Surface

Class B will the surface we will add engineerning feature, to create Class B, I have fellow below steps

• First offset Class A Surface 2.5 mm.
• After seeing offset we will see that some fillets are not there in the offset.

• I have use MULTIPLE EXTRACT command and selected the fillets, in which i have to work.
• After selecting fillets , click on complementary mode.

• Select Multiple extract and use disasssemble , to divide surface into 4 parts, in below different colour 4 surface after disassemble.

Joining of Blue+Brown Surface

• Now we will join blue and brown part.
• Use boundary operation on brown surface and extrapolate it (10mm), and i named it as " 2nd surface extrapol".
• Use boundary operation on Blue surface and extrapolate it(10mm), and i named it as " Main surface extrapol".
• Trim them (below image will the result of the trim)

JOINING OF ABOVE BROWN WITH REMAINING TWO SURFACE

• Use boundary operation on LIGHT BLUE(walls) surface and extrapolate it (25mm), and i named it as " 3rd surface extrapol".
• Now i have extrapolated PINK surface ,and named the final extrapolate as "4th patch final Extrapol".
• Now i have extrapolated MAIN surface(above brown image), and named it as "main patch extrapolate".
• Now i have trim in the order as shown in below image

• Below image is result of the trim

• Now only one patch is remaining as shown above image(red mark).
• I have used multi-selections surface in this but it was not joining properly.
• So to fix that problem , i used join operation and using remove mode i remove trapezium part.

• Now use boundary operation, to get the guided curve for multi-selection surface.
• I used Multi-selection surface and join it(MSS)with a extract.
• Now we will provide fillets
• Since we cannot tell fillet by see our class A surface because we are getting length value.
• So i use any middle face of the fillets(which value we have to find) and extract it ,
• using boundary command i got a curve, and made a point on the centre of that curve.
• Now using 3 points and i made a circle and find the radius value of that fillet .
• i subracted with 2.5mm to get the value of B-surface fillets.

B-SURFACE

• I have extrapulated some edges of B-surface because it can intersect C suface properly.

Step-5 Class-C Surface

NOTE- While i working on C-surface,i notice a very small triangle cut(below image) in Class A surface, so i improved class A surface.

I have drawn a line and extrude it and used split.

C-surface for outside boundarys(1st)

• Use bondary operation and extract the ouside boundary.
• And now i used sweep using reference surface.
• I have taken angle 93 degree and angular sector 1.

• I now notice that some C-surface were not proper
• so I used multiple extract and using complementary mode i removed improper parts(both side).
• Below image show that area

• Using multi-section surface i added again these removed area.
• And join both multi-section surface with previous multiple extract.
• I also noticed some part of class A was showing red while draft analysis.
• So i used join operation and with the help of remove mode i removed the area of c surface which was craeting problem while draft analysis.
• Now i have work on the removed area.
• I used boundary opertion, and used sweep using draft direction.(3degre)

• The remain 2 area i have again used multi section surface,
• After join the all ,my C- surface for outside boundary ready.
• Now extract the inside boundary of class A surface, using Boundary command.
• Use sweep using reference surface.
• Join both C surface, This will be our class C surface.

• Join this C surface with Class A surface and after that trim it.
• Below image shows Class (A+B+C).

Step -6 Draft analysis report for the final plastic component with engineering features

Draft analysis tell whether our component is manufacturable or not, if it's green it clears but if it's red means the surface is not clearing.

My all area is clearing expect a very small portion in C surface, it is happening becausing in that part my angle is changing from -ive to +ive .

Step-7 CONSTRUCTION OF HEAT STAKE

So from above Image we can say that we have to make two 4way locator and remaing are heat stake.

HEAT STAKING- It is method of assembly , in which plastic (theromplastic polymer) stud or boss is heated and then cooled to assemble/lock with other components.

Some of Advantages are

1. Simplification of machinary
2. Does not require extra parts for fixing
3. Reduce cost,etc.

To make Heat staking we need to fellow following steps-

• Since we have got some points as input
• I have extracted 1 face
• And made a plane tangent to extract surface, at any given input point.
• Now draw a sketch as show below.

• these circle will be our inner and outside wall.
• Now in part workbench pad them

• I have taken diection as tooling axis.
• Now apply the outside as well inside draft separatly.

• this is our 1st Heating stake, now using translation feature i have made on other 13 points.
• So first copy the heat stake body and right click on "Door Trim - Heat Stake & Locator" and select on paste special.
• And click on "As result with link" and press OK.
• Now use translation and using point -point select the end point, as the point where we want to place the heat stake.
• Now after doing for all 14 heat stake , union trim with main body.
• And remove unwanted parts.
• Apply the fillels and Heat stakes are ready.

Step-7 CONSTRUCTION OF LOCATORS

LOCATORS - Locator is basically used to restict the translation as well as rotatioal movement of a components.

• For locator we will use same plane which was used for heat stake,
• So draw a sketch as show below.

• Now we wiil pad it,also tick on thick, taking direction as tooling axis.

• I have taken thickness of components as 1.2mm
• Provide the draft and take draft angle as 0.5 degree, and provide champer

• Now provide fillets , and our locator is ready.

• To create other locator i have used translate feature and repeated same step as for heat stake
• Now union trim both the locator with main part.

The height of our locator should be more than heat stake.

Average Height of Locator =21mm

Average Height of heat stake = 14.3mm

Step -8 Draft analysis report for the final plastic component

• Since we are doing draft analysis for locator and heat staking , so draft angle will be 0.48degree.

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