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

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.

Create the Heat Stakes and the locators considering the design rules mentioned in the video for the door applique.

STEPS FOLLOWED:

1. Tooling Axis Creation.
2. Draft Analysis of Class A surface.
3. Creating Class B surface and Class C surface.
4. Creating a Closed body of component Door Trim.
5. Draft analysis for Door Trim Component.
6. Creating the Sketches of 4 Way Locators and make them as Solid Body using Part Design.
7. Apply Draft angle , Chamfer, Edge Fillet to the Locators and Unitrim with Closed Body.
8. Creating the Sketches of the Heat Stakes and make them solid features in Part Design.
9. Apply Draft Angle , Chamfer, Edge Fillets to it.
10. Paste with the special link and Translate the Heat Stakes where they are required and Unitrim them with Door Trim Component.
11. Creating the Sketches of Dog House profile as per the given guidelines.
12. Solid Profile creating for the Dog House using Thick Surface Union Trim them to the Closed Partbody.
13. Given the Draft angle and Edge Fillet Radius to the require faces as per the Guidelines.
14. Check the parameters of Locators, Heat Stakes and Dog Houses that were is per Guidelines and standarts.
15. Perform the Draft Analysis for Door Trim Assembly.

Commands used Boundary, Extract, Multiextract, Trim, Join, Sweep, Point, Line, Circle , Draft, Chanfer, Edge Fillet, Draft Analysis, Closed Body, Thick Surface, Pad, Unitrim, Remove, Intersection.

Key Terms:

TOOLING AXIS:

• It is the direction of Mold's Core & Cavity moves.
• The Tooling Direction is basically the direction that the mold pulls apart.
• The mold is built in two separate pieces, Cavity side & Core side.
• The Core pulls apart from the Cavity and that's the Tooling Direction.
• The Line of Direction or Axis followed is Tooling Axis.

CLASS A SURFACE:

• Class A surface means Visible surface of the Component or part.
• It is the base reference to the creation of B & C surfaces that forms the Component.
• It provides the Aesthetic Appreance to the component.

CLASS B SURFACE:

• It is the mostly the Non-Visible Surface area
• It is the behind the Class A surface .
• It helps in the Parting surface creation.
• Flashes and Missmatches are done in the Class B surface , that will not distrub the Class A surface.

CLASS C SURFACE:

• It connetcs the Class A surface and Class B surface of the component.
• It also describes the Thickness of the Component.

DRAFT ANALYSIS:

• The Draft Analysis technique is used to analyze whether our Part model created is Manufacturable or not.
• Based on the Draft condition and Tooling Axis applied, Here the part should get easily removed from the Mold (Core & Cavity).

DOG HOUSE:

• It Avoid Sink Marks on Class A surface.
• It also arrests the Degress of fredom of component.
• Engineering features like snaps, locators , Screw Bosses etc. are mounded on them to increase their strength.

LOCATORS:

• These aremainly used to Arrest the Degrees of Freedom of the Plastic Component.
• Usually There are 2 way and 4 way Locators.
• Same rules as the Ribs are Followed.
• It also supports the Position of Plastic Component While Assembly or Joining of Components.

HEAT STAKES:

• Heat staking also known as Thermoplastic staking is the process of joining two Plastic Components together.
• Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic.
• The bond is made by partially de-forming the plastic part in order to fix the other.
• These Helps in Not forming the Heat Sinks , and B side deffetcts of Platic Components.
• These helps mostly in Locating and Used for Fastners Supports.

PROCEDURE:

Checking the given Class A Surface.

• Checked the Class A surface is a Closed profile by using the Boundary command.
• The complete profile has only one Boundary at the outer edge without breakage.

TOOLING AXIS:

• Checked the all the posibilites of Draft Tooling Axis in all directions so that the most of the surface area visible
• Confirmed that the it would be in Y direction.
• Created a point on Profile and created a line in Y-Direction as the Dummy Tooling axis.
• Performed the Draft Analysis and all the surface is clearing the Minimum 3Deg Draft and the Dummy Tooling Axis as Tooling Axis.
• As the Class A is clearing the Draft Analysis Bisection Method is not required.
• Cleating A line Perpendicular to Tooling Axis at the same point in Z-Direction for as the Side Core Tooling Axis for the Dog House.

X-Direction

Y-Direction

Z-Direction

Tooling Axis

Side Core Tooling Axis

DRAFT ANALYSIS:

• Select into the Material Mode and Insert the Feature Draft Analysis.
• Select the Compass place in the Tooling Axis Direction and Activate the Compass , adjust the compass to the Tooling Axis Direction.
• Provide the Minimum Draft angle is 3Deg.
• Select the surface So that the Green Area that is Draft angle is more than 3Deg angle and it is Manufacturable.

Creating Class B Surface:

Class B surface is mostly the not visible surface and it is the back of the Class A surface.

• Offset the Class A surface for 2.5mm (Thickness of Component is 2.5mm).
• The offset surface has the Patches that the minimum fillet value placess cant be offset.
• All The Patched surfaces are Extarcted by using the Extract & Multi Extract Commands.
• Then the Surfaces are Extrapolated untill the Intersection done.
• Then the both Intersection Surfaces are Trimed by using Trim command.
• All the surfaces are Checked for the patches.
• Cross checked gap between the two surfaces Class A and Class B surfaces found that to be 2.5 mm.
• Edges on the Class B surface are Extrapolated to get an intersection with Class C Surface.

Offset Surface

Extracted and Extapolated Surfaces

Trimed Base Surfaces

Side Profile

Final Trim with out fllets

Fillets:

• The finished surface is provided the Fillet vallues.
• The thickness should be added or subtracted to the fillet value based on the direction of it with reference to the Class A surface.
• Checked the remaning surfaces that all are filleted and there were no sharpedges found on it.
• Finding the Radius of the Surface is create a mid point on the curve and creating a circle by using the Three points (Two edges and Mid point).
• Mesure the Radius on created circle arc on the outer profile.
• Apply the measured fillet to the Edge Fillet one.
• The Minimum fillet radius is given that 0.5mm.
• The Final Surface is Extrapolated on the Edges so that It can be easily trimed with Class A and C surface.

Creating an Arc to finding the Radius of Fillets

Fillets to the B surface

Extrapolated Class B surface.

Class C Surface:

Class C Surface is that connect the Class A Surface and Class B Surface.

• Create a boundary on the Class A surface at the individual corner and then Sweep it individually to avoid the patches.
• By using the Sweep Command with the reference of Class A surface and angle of 87Deg to it(3Deg for the Draft Clearence).
• The Central part of the Surface is Sweep in the both directions and trimed with the Class A Surface to avoid the gap and patches formed between Class A surface and Class C surface at the center while joining them.
• The thickness or length of the Class C Surface is 4mm minimum, so that it will be trimed easily with Class B Surface.
• Then the individual surfaces of Class A and Class C are Joined by using the Join Command.

Class C surface sweep

Class C surface

Trimed the Class A and Class C to Avoid Joining Patches

Closed Surface:

• The Trimed surface is formed.
• Created a Boundary on the Trimed Surface so that it inssures that no boundary formed. Confirms that it is completely closed.
• By using the Closed surface Command in the Part Body Design to the surface body.
• Now the Solid Body is formed.

LOCATORS & HEAT STAKES:

• Created a sketch using the Position Sketch and refence plane and point the sketch is drawn.
• Created a solid Body in the part Design by using the commands Pad.
• Apply the Solid Features to it like Edge Fillet, Draft Angle, Chamfer etc to it
• Paste as a special link and Translate them to the points as required.
• Assembly the Locators and Heat Stakes as one Body separately.
• Unitrim with the main Part Body

Locator Height 15mm that

Locators Tree Structure

Heat Stakes

Height of Heat Stake is 10mm and 5mm less than locator

Heat Stakes Tree Structure

Dog House:

• Create Sketch of Dog House And Iso constrained it in the Position Sketch
• Extrude It to the certain height.
• Offset the base plane and Trim with the Extruded Profile.
• Now Thick Surface The Closed Profile and Split up the Required Width .
• Now Prowide The Draft Angle of 1.5Deg outer and 0.5Deg inner with reference as Back side of profile as neutral element.
• Now create a cut profile at the bottom side and split it for the Required width of 1mm and at a height of 5mm.
• Now prowide the Fillet Radius as 1mm inner and 3mm outer and 0.5 at the cut profiles.
• Now perform the Draft Analysis for Dog House and For Component.

Thickness at base is 0.76mm

Height of Step is 5.196 and range should be in 4-6mm

minimum fillet radius is 0.5mm

Dog House Tree Structure

Locators Sketches

Heat Stakes Sketches

Dog House Sketches

Removed Profile of Dog House

Dog house, Heat Stakes and Locators

Requirement

Created Profile

DRAFT ANALYSIS:

• Select the Draft Analysis to the ClOSED SURFACE.
• Select the Axis and place the Axis line along the Tooling Axis direction.
• Select the Draft angle degree as 3Deg minimum.
• Selected the Surface and found in Green Colour in all the surface area in the Draft Direction.
• Checked the inversion of Drafting to the Core side and Cavity side.
• Cross checked the angle of draft at all surfaces and found that is more than 3 deg.
• Checked the Draft Angle as 1.5Deg for the Dog House Exterior in the Tooling Axis direction.
• Checked the Draft angle as 0.48Deg that is approx to 0.5Deg for the Heat Stakes and Locators are clearing the Draft Analysis in the same Tooling Axis Direction.
• Now Changed the Compass to the Side Core Tooling Axis and activated it.
• Checked the Draft Analysis for the Interior of the Dog House clearing the minimum of 0.5Deg of Draft Angle.

Door Ttrim Draft Anlysis of 3Deg Draft Angle

Draft Analysis for Heat Stakes & Locators

Dog House Interior Draft Analysis 0.48Deg with Side Core Tooling Axis

Isometric View

Front view

Back View

Left view

Right View

Top View

Botttom View

Multi Section View

Tree Structure