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

DOOR TRIM LOWER WITH ENGINEERING FEATURES ( Heat Stakes & Locators )

Aim:

To Create the Door trim lower component through the given Class-A surface & to design engineering features such as Locators & Heat Stakes.

Take the Thickness of the component to be 2.5 mm

INTRODUCTION:

CLASS-A SURFACE: A surface made by the designer which is given as input to the plastic modeler to work on. It is an aesthetic surface
and the outermost surface.

CLASS-B SURFACE: A surface below a certain thickness from the class-A surface is a class-B surface. This is the surface that contains
engineering aspects of a model.

CLASS-C SURFACE: A surface that joins class-A and class-B surfaces is a class-C surface.

Methodology :

In this design we will focus on the following steps

1. Tooling Axis
2. Draft Analysis
3. Class B Surface
4. Class C Surface
5. Making a solid model from Class A surface

Following tools were used to reach the final Solid Model :

1. Extract
2. Un - trim
3. Trim
4. Offset
5. Extrapolate
6. Boundary
7. Edge Fillet
8. Sweep
9. Join
10. Close Surface ( Part Design )

TOOLING AXIS

Tooling Axis for Plastic Part :

Tooling direction is main consideration for plastic part and mold parts because it defines movement of mold part and possibility of plastic part to come-out from mold part (Core and Cavity).

• In Molding machine arrangement is given to open the mold along a direction which is known as Tooling Direction.
• In other words. The mold is built from two separate halves (Core and Cavity) and tooling direction basically define the direction of mold pulls apart.
• Tooling direction is known as primary direction.

In this given Bumper Class A surface the tooling axis is created using inertia method as shown in the fig below -

FOR CLASS B SURFACE :

1. Invisible Surfaces.
2. Surface mostly don't have textures
3. Surface needs to be created according to the class-A surface.
4. Having all features in B-side surface only.
5. Surfaces which is having TANGENT CONTINUITY IS CALLED class-B

Just Offseted the Class A for 2.5 mm & performed some modifications as per requirement.

FOR CLASS C SURFACE:

Took boundries for class A in some sections and in other sections took Multiple extract for Class A Surface.

Sweept using boundries and Multiple Extract with Reference surface.

CLASS A CLASS C TRIM

Final Trim -

Class A + Class B + Class C

LOCATORS & HEAT STAKES

DESIGN OF 4 WAY LOCATORS :

Take gemoetrical set and draw sketch with reference of plane and projection point & then give PAD for the sketch with in the dimension limits selecting NEUTRAL FIBER .

Thickness = 1.3

Draft Value = 0.5

Apply Fillets where required - 0.3 mm or 0.5 mm

There are two 4 WAY LOCATOR on the model as shown in the figure in question .

Sketch -

DESIGN OF 4 WAY LOCATORS -

Take gemoetrical set and draw sketch with reference of plane and projection point & then give PAD for the sketch with in the dimension limits selecting NEUTRAL FIBER .

Thickness = 1.3

Draft Value = 0.5

Apply Fillets where required - 0.3 mm or 0.5 mm

There are six 2 WAY LOCATOR on the model as shown in the figure in question

Sketch -

DESIGN OF HEAT STAKES WITH RIBS :

Take gemoetrical set and drawn a sketch with reference of plane and projection point apply PAD for the sketch with in the dimension limits by NEUTRAL FIBER.

DRAFT Value = 0.5

Apply Fillets where required - 0.3 mm or 0.5 mm .

There are 16 Heat stakes on 16 different points in the model as shown in the figure in question .

Sketch -

DRAFT ANALYSIS :

Class A surface draft analysis:

The above image shows the draft analysis in which green color surfaces shows that they are having an angle of more than 3 degrees but the surface in red color shows it is less than 3 degree. These are the results of the draft analysis which are very crucial for determining the feasibility of the product

Solid component draft analysis :

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour range identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values. After draft analysis done we can observe that the green colour shows that the drafted walls of the switch bezel are above 3 degrees which is a permissible criteria to manufacture in injection moulding.

Draft Analysis with For Final Body with Attachment Features -

SOLID MOULD :

TREE STRUCTURE :

CONCLUSION:

• The Tooling axis and the SolidCAT part with B Side Features ( Heat Stakes & Locators ) is created from the given Class A Surface and Draft Analysis is Performed.