Challenge

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

SSrota Das20 Dec 2022

Project 1 - Door Trim Lower with Engineering Features

AIM

To study the creation of locator and heat stakes.

OBJECTIVE

Create the Door Trim Lower Plastic component through the given Class-A surface. To begin with, 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.

THEORY

Heat Stakes design :-

Counter Part Thickness - Will be given as input

Component Wall Thickness - Will be given as input

Length of the Rib - 22 mm

Height of the Ribs - 3 mm to 6 mm

Inner Diameter of Heat Stake (d) - 5 mm

Outer Diameter of Heat Stake (d) - 7 mm

Minimum clearance between heat stake and counterpart - 0.5 mm

Height of the Heat stake - Depends on the rib height and counter-part thickness

Minimum fillet of Heat Stakes - 0.25 mm

Minimum Draft Angle of Heat Stakes - 0.5 degrees

Locator:

Height of the locators should be 1 mm (or) 2 mm greater than the heat stakes

Thickness, fillet and draft angle are of same as rib design rules.

Ideal Chamfer value - 5 mm x 45 degrees

Ideal length of the locators - 15 mm

TOOLING AXIS

Here the tooling axis is created parallel to the Y axis because in this direction we can see the whole surface and surface is not planar. Extract the surface then create one point and create line (Point - Direction).

DRAFT ANALYSIS OF CLASS A SURFACE

Here draft analysis carried for class A surface with respect to tooling axis. Here colour code used is a green colour indicating that the draft is 3 degree or above. The red colour indicates that the draft is 0 degree and the blue colour indicates that the draft is minus value. From draft analysis we can see that green colour is all over the surface and hence it is suitable for further process because it follows optimum draft.

Heat Stake:

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.

REASONS FOR HEAT STAKING:

1.Mutiple staking shapes for different benefits.

2.Excellent durability.

3.No extra materials are needed.

4.Increased efficiency.

5.Easy Maintenance.