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

DOOR TRIM LOWER - CLOSED SURFACE FEATURE

AIM:

To create a Door Trim Lower Plastic Component using a Class 'A' Surface and by using the Closed Surface Feature to create a solid part from the surface and to create the 4 way Locators, Heat stakes, Dog House and Ribs on the B surface as a attachment features.

OBJECTIVE:

• To Create a Plastic Component by using the Class 'A' surface.
• To create a Tooling axis for a class 'A' Surface, which meeting the requirement of the draft angle and to analyse the solid model.
• To create a solid model from the surface using the Closed Surface Feature with the thickness of the component wil be 2.5mm.
• To create a Attachement feature 4 - Way Locators, Heat Stakes, Dog House and Ribs on the created Class B Surface.
• To create a report which explains the Draft analysis and Tooling Axis cration and colour scale varient.
• To attach the screenshots of the expanded Tree Structure for the Geometrical Sets .
• To attach the screenshots of the 3D Part Model in different orientations.

PUBLICATION:

• Class 'A' Surface.
• Tooling Axis.
• Class 'B' Surface.
• Class 'C' Surface.
• Door Trim Lower Solid part
• Side Core Axis

INTRODUCTION:

TOOLING DIRECTION:

The Tooling Direction is the direction that the mold pulls apart. The mold is built in two separate pieces,

• A Cavity side and
• The Core side.

The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction. The direction in which the mold or core and cavity opens is the tooling axis.

FEATURES OF TOOL:

CATIA 3-D SURFACE SOLID PART MODEL - CLOSED SURFACE FEATURE

CLASS 'A' SURFACE:

DESIGN CHECK:

The Class A Surface are Checked Visually by using the Join Feature or by using the boundary feature the Class A surface are selceted and Disassembled the Surface to check the surface are created without the gaps.

The Class A Surface should be created without the boundary Gaps. By using the Join Definition with the Merging distance of 0.001 mm the Class A surface are Joined Together to check the connectivity.

PUBLISHING THE CLASS A SURFACE:

By using the Publication option the Class A Surface are Published. The Publication is used to retrive the Class A surface in the easier way to use from the Structured Tree Implementation.

CREATING TOOLING AXIS:

The Tooling for the Class A Surface are Created in the diection in which the parts are getting Ejected from the Tool. The Tooling Axis which defines the core and cavity pulls apart from the Tooling Direction.

In the Door Trim Lower Class A plastic component the base are been extracted to create a tooling axis on the surfaces.

By using the Point Definition, The point type has been selected on surface and direction along y components are been selected.

By using the Line definition feature by the line type as Point - Direction the line has bee created as a Main Tooling Axis.

MATERIAL MODES:

For the Draft Analysis, the material modes are Selected from the Shading Type.

DRAFT ANAYSIS ON CLASS A SURFACE:

For a Class A Surface, The Draft analysis are to be performed in order to meeting te requirement of the draft angle to the required Tooling Axis. For Plastic component the Minimum angle required for the daft to be 3 degrees. The Direction compass are to be selected and placed it on the Main Tooling Axis line and the comass are been locked using the lock feature in the direction.

In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,

• For 3 degeree - Green Colour Varient (Positive)
• For 0 degeree - Red colour varient.
• For Negative degeree- Blue colour Varient.

By Using the Running pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 85.787 Degeree Direction.

The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are implied as Blue colour.

CREATION OF CLASS 'B' SURFACE:

By using the Class A Surface the Class B Surface are created by offsetting to the respective length to th respective direction. By using the offset surface definition the class A Surface are been offsetted to the length of 2.5 mm from the direction towards downward.

By using the Multiple Extract definition feature the offsetted surface are been selcetd in order to remove the excess element from the created offseted surfaces. By using the Mulitiple Extract to Remove Sub - elements the partial fillets and the areas are been removed.

By using the Multiple Extract definition feature the offsetted surface are been selcetd in order to remove the excess element from the created offseted surfaces. By using the Mulitiple Extract to Remove Sub - elements the partial fillets and the areas are been removed.

By using the Boundary feature the outer strip are been selected in order to extraploate the surfaces. By using the Extrapolate feature the boundary surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting the features the boundaries are been extrapolated to the respective length provided.

By using the Multiple Extract definition feature the offsetted surface are been selcetd in order to remove the excess element from the created offseted surfaces. By using the Mulitiple Extract to Remove Sub - elements the partial fillets and the areas are been removed.

By using the Boundary definition the limits are been selected by using that the boundaries are been extrapolated to the respetive lengths.

By using the Extrapolate feature the boundary surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting the features the boundaries are been extrapolated to the respective length provided.

By using the Multiple Extract feature the elements are been selected from the class A Surface.

By using the Trim definition feature the extrapolated surfaces are been selected and trimmed with each other to form the surface as Class A Surfaces.

By using the Trim definition feature the extrapolated surfaces are been selected and trimmed with each other to form the surface as Class A Surfaces.

By using the Multi surface definition the sections and te guides are been selected and the surfaces are been created.

By using the Edge Fillet Definition the fillets are been provided on the edges created with the trimming operation.

The Class B Surface are Checked Visually by using the Join Feature or by using the boundary feature the Class B surface are selceted and Disassembled the Surface to check the surface are created without the gaps.

The Class B Surface should be created without the boundary Gaps. By using the Join Definition with the Merging distance of 0.001 mm the Class A surface are Joined Together to check the connectivity.

CREATING CLASS 'C' SURFACE:

To make the Class C Surface, the Boundaries are been Extracted from the Class A Surface. The Cover area Boundary, are been extracted using the Bundary feature/ EXtract definitions.

By using the boundary definition the outer area Boundaries are been selected by using the limits.

By using the Sweep surface Creation definition, The respective profile type are been selected and subtype with reference surface are been selected. In that the Guide curve are selected as the. Boundary in the Class A Surface, and reference surface are selected with the draft angle of 90 degree are performed and the creation of Class C Surface.

The Class C Surfaces are been created by using the sweep feature and also the Direction along the Tooling direction and the reference with the surface and guide curve are been selected to form the Class C Surfaces.

JOINING CLASS A AND CLASS C:

By using the Join feature the Class A and Class C Surface are Joined Together with the Merging Distance of 0.001 mm.

FINAL TRIMMING:

The Final Trimming Has been performed on the Class B and Joined Class A and C surfaces. The Trimming has been performed.

CLOSED SURFACE:

By using the close surface definition the part surface are selected to make them into solid part from the part workbench.

MEASUREMENT:

The Door Trim Lower are created with thickness of 2.5 mm using the surface features.

CREATING B SURFACE ATTACHMENT FEATURES LOCATORS, HEAT STAKES, RIBS & DOG HOUSES

CREATING 4 WAY LOCATORS ON B SURFACE:

By using the Multile Extract Definition the locator surfaces are been extracted.

By using the Point definition the points are place don thesurfaces @ the locators distance with the specified directions.

By using the positioned sketch the Extracted surface are been selected and the locator lines are been drawn and the sketches are been Iso - constrained using the repective geometrical and dimensional constraints.

By using the Pad definition the 2 - D sketches are been extruded to the thick and tje first and second limit lents aren been definird to the respective lengt to the respective direction.

By uisng the drfat definition the faces are been selected to draft and the pulling dircetion are been selected as a Main tooling axis also the neutral element to draft are been selected.

By using the champfer and the edge fillet definition the respective values are provided as per the design rules @ fillet radiiis 0.25 mm.

By using the Boolean opeartion Union Trim the locators are been trimmed by selecting the remove faces and added wit the main part body.

By using the Translate feature the locators are been translated usin the co- ordinate points with the respective direction.

HEAT STAKE CREATION ON B SURFACE:

As per the design rules the Heat Stake Bosses are been created, The Solid part for the Door Trim Lower are been created with the thickness of 2.5 mm. For the Door Handle the Screw Boss Calculation are as follows,

(1). HEIGHT/DIA RATIO = `3:1`

(2). WALL THICKNESS = 40 % NOMINAL WALL @ BASE SIDES

(3). RIB FILLET RADII = `0.25 mm`

(4). WALL DRAFT = `0.5 deg`

By using the positioned sketch the Extracted surface are been selected and the screw circles are been drawn and the sketches are been Iso - constrained using the repective geometrical and dimensional constraints.

By using the Pad definition the 2 D sketch are been extruded to the respective lengths as per the design rule of screw bosses.

By using the Draft definition the inner and outer areas are been selected for the draft analysis and the neutral elements are been selected as the extracted elemet with respectto the pulling directions as main tooling directions.

For the Support for the Heat stake Bosses the Supporting Ribs are been added to the screw side faces. For that the supporting Rib sketch are been drawn and by using the pad definition the 2 D sketch are been extruded to the respective lengths.

The Boolean operation Union Trim are been performed on the created ribs and the faces to remove are been selected and the Screw Bosses with the supporting Ribs are been formed in the solid part on the Class B surface.

The Heat stakes with the supporting Rib profiles are been selected and using the translate feature the another heat stakes are been created to the respective lengths.

By using the Edge fillets the Heat stakes and supporting rib faces are been filleted to the respective radii 0.25 mm and by suing the Union Trim definition the face to keep are been selected and Trimmed with the part body.

CREATING RIBS ON B SURFACE:

CALCULATION FOR THE RIB DESIGN:

As per the design rules the Ribes are been created, The Solid part for the Door Handle are been created with the thickness of 2.5 mm. For the Door Handle the Calculation are as follows,

(1). RIB LENGTH = `5*2.5 mm` `= 12.5 mm`

(2). RIB THICKNESS = `0.4*2.5 mm``=1.00 mm`

(3). RIB FILLET RADII = `0.25 mm`

(4). RIB DRAFT = `0.5 deg`

(5). RIN THICK @ TIP = `0.75 mm`

By using the positioned sketch the extracted surface are been selected and by using A Positioned Sketch the line has been created is a sketch that has its origin location or orientation defined with construction geometry. As the construction geometry changes the sketch position or orientation will change accordingly.

The Main tooling axis has been selected as projection point in which the defined point are selected based on the references. As per the design rules the Ribes rae created with the extruded length of 12.5 mm by calculating with respect to the thickness of the solid part. By using the thickn feature the Extruded surface are been thickned to 1 mm as per the design rules.

By using the draft definition the fcaes are been selected in order to do the drafting on the faces of the ribs. Thre neutral elements are been selected as a extracted face and the pulling direction are been selected as a Main tolling direction.

The Boolean operation Union Trim are been performed on the created ribs and the faces to remove are been selected and the ribs are been formed in the solid part on the Class B surface. The edge fillets are been performed as per the design rules 0.25 mm at the faces of the Ribs. The fillet operation are been performed.

CALCULATION FOR THE DOG HOUSE DESIGN:

As per the design rules the Dog House are been created, The Solid part for the Door Trim are been created with the thickness of 2.5 mm. For the Door Trim the Calculation are as follows,

(1). PART WALL THICK (T) = `2.5 mm`

(2). Intersection Surface (C) = `0.4*2.5 mm``=1.00 mm`

(3). Height Of B = `4 mm`

(4). DRAFT = `1.5 deg`

By using the positioned sketch the extracted surface are been selected and by using A Positioned Sketch the line has been created is a sketch that has its origin location or orientation defined with construction geometry. As the construction geometry changes the sketch position or orientation will change accordingly.

By using the sweep feature the created sketchs are been extruded to the respective length to the respective directions.

By using the Line definition the side core tooling axis are been created in order to clear the draft analysis of the Dod house Design oN the Class B Surface.

By using the thickn feature the Extruded surface are been thickned to 2 mm as per the design rules.By using the Extraction of the surfaces the intersections on the class B side are been Trimmed off. By using the split definition the trimmed surfaces are splitted into the Dog House to form the Intersection @ the Class B Surfaces. By using the Drfat Definition the faces are been selected to draft along the side core pulling direction.

The draft is Provided @ the bottom surface t the angle og 0.5 deg and also the pulling direction as side core axis.

By using the edge fillet definition the Edges are been filleted to the respective radii @ 0.25 mm. By using the Boolean operation Add feature the Dog House 1 are been Added with the Door Trim LowerSolid Component.

By using the Translate feature the Dog House are been copied and translated to the respective length and the distence.

By using the Rotate feature definition the Dog Houses are been Rotated with the help of Axis system to the respective directions. By using the Boolean operation Add feature the Dog House are been Added with the Door Trim Solid Component.

By using the positioned sketch the Extracted surface are been selected and the Profiles are been drawn and the sketches are been Iso - constrained using the repective geometrical and dimensional constraints.

By using the pad definition the profiles are been extruded and using the Boolean opearation Remove feature the extruded profiles are been trimmed with the Dog Houses.

DRAFT ANALYSIS:

The Draft Analysis has been performed on the Fianl component created as a closed body using the part design Closed Surface Feature. For Plastic component the Minimum angle required for the daft to be 3 degrees.

The Direction compass are to be selected and placed it on the Main Tooling Axis line and the compass are been locked using the lock feature in the direction.

The locators draft analysis are been performed to the axis along the Main Tooling axis by positioning the compass on the Tooling axis and wit the draft 0f 0.45 degere are been provided on the faces wit are been cleared with the main tooling axis.

The Ribs and Heat Stake draft analysis are been performed to the axis along the Main Tooling axis by positioning the compass on the Tooling axis and wit the draft 0f 0.45 degere are been provided on the faces wit are been cleared with the main tooling axis.

In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,

• For 3 degeree - Green Colour Varient (Positive)
• For 0 degeree - Red colour varient.
• For Negative degeree- Blue colour Varient.

By Using the pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 80.538 degeree angle.

The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are imled as Blue colour.

EXPANDED TREE STRUCTURE:

In CATIA the sketches and te surface operations are been defined using the Geometrical sets. By using the profiles like line, circle, hexagon, polygon, arc the 2 -D sketches are been created with reference to the Geometrical sets. According to the selection of plane from the possitioned sketch the 2-D sketch has drawn with the referene plane.

The surface opeartions like Extrude, extract, trim, split, edge fillets, surface untrim, sweep, smooth curves, extrapolating, Boundary and Fills are deined using te respective geometrical sets.

PUBLICATIONS:

The Class A,B,C and the main Tooling Axis are been published using the publication option. The Door Trim Lower solid part are also published using publication option.

3 DIMENSION PART AND ORIENTATIONS:

ISOMETRIC VIEW, FRONT VIEW, SIDE VIEW AND BOTTOM VIEW:

CONCLUSION:

• The Door Trim Lower Plastic Part Component using the Class 'A' surface are Created.
• The Tooling axis and side core axis for a class 'A' Surface, which meeting the requirement of the draft angle are analysed and perfrmed.
• The solid model from the surface are created by using the Closed Surface Feature.
• The Attachement feature 4 - Way Locators, Heat Stakes, Dog House and Ribs on the created Class B Surface are been created as an attachment features.
  
• The detailed report which explains the Draft analysis and Tooling Axis cration and colour scale varient are explained.
• The Class A, B and C surfaces are Published using the publication option.
• The expanded Tree Structure for the Geometrical Sets are explored .
• The expanded tree structure for part design are explored.
• The 3D part Model with various orientations are attached.