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

Aim : To create a model of door trim lower design from given class A surface and add engineering features like heat stakes and locators and to do draft analysis.

Objective :

• To create class B and class C surface .
• To do draft analysis .
• To add engineering features and perform draft analysis of it .
• To make report of it .

Introduction :

Class A surface :

• It is asthetic part of car created through scaning of clay model .
• This is the input CAD model for part design .

Class B surface :

• It is surface for engineering advancement .
• It is created at the thickness value of component toward inside .

Class C surface :

• class C surface is created by joining class A and class B surface .

Methodology :

• checking continuity of surface.
• Tooling axis.
• Draft analysis.
• Class B surface.
• Class C surface .
• Making solid body .
• Adding engineering features like heat stakes and locators.
• Draft analysis of final product .

Tooling axis :

• The direction in which the mould open and close is called tooling direction.
• Extract the base and create the point at the center .
• from that point creat line which is tooling axis.

Given class A surface :

Tooling axis :

B surface creation :

• offseting class A surface inward by 2.5 mm which is the thickness .
• By ofsetting class A surface , some patches are created .
• repairing it through join , extrude ,sweep , multiple extract , trim command.

Final Class B surface :

Creation of C surface :

• Boundary of class A surface is extracted and middle portion is also extracted .
• Sweep command is used to create C surface at 90 degree of class surface .
• class C and class B are trimed and join with class A surface .

Creating solid body :

Finally solid is body is created by using close surface command .

Draft analysis :

• First the material mode is selected in custumize view swction.
• Now click on the compass tab and align it with tooling axis .
• Now click on the lock .
• click on the surface .
• Surface colour shows green , which mean that the it has more than 3 degree angle , which is good for manufacturing .

Class A surface :

Final body :

Different views are as :

Isometric view :

Front view :

Side view :

Top view :

Adding engineering features :

locators and heat stakes :

• The heat stakes is used to join components.
• will enter the mating component and using a heat staking machine these heat stakes are melted and cooled.
• When it gets cooled down both part will mate with each other.
• Thus all degrees of freedom are arrested .
• The ribs for heat stake are created by following the rib design rules.
• Hence, the ribs are created for the screw HEAT STAKES.
• The door applique is fixed on to the door surface with the help of locators and heat stakes.
• Every component in space has 12 degrees of freedom.
• So these locators and heat stakes restrict all these degrees of freedom.
• Locators are 4-way locators and 2 ways locators .
• The locators will follow the rib design guidelines and will be given a minimum draft of 0.5 degrees and a minimum fillet of 0.2mm and an entry chamfer of 3mm.
• This entry chamfer is given so that the locators can mate with the other part easily.

Draft analysis of body with heat stakes and locators :

Different views:

Isometric:

front :

right :

Tree structure :

Publication :

Conclusion:

• Created class B surface and class C surface for door trim .
• crestred engineering features .
• Perform draft analysis .