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

Aim:

To create the Door Trim Lower Plastic component through the given Class-A surface and also to create the Heat Stakes and the locators considering the design rules.

Class A Surface:

The Class A surface is gives is shown in below image:

Procedure:

Step 1 : Connectivity of the Class A Surface

• Check the connectivity of the Class A Surface that is to check that there is no gap between the components using the Join command or by visual inspection or also by using the Boundary Command.

Step 2 : Tooling Axis

• The Tooling Axis is created using Bisecting Line Method.

Bisecting Line Method:

In Bisecting Line method is that the possiblities or clearance is checked along the direction using the intersection of surfaces along the axis on the plane of the Class A surface and the two lines is created on the intersections walls that is along the inclined walls of the intersections. Then the line is created by using bisecting line option in line command using the two lines and the point created and that line is Tooling axis.

• For Creating tooling axis we create the point. The image of point is shown below

• Then the intersection is created using XY plane using Axis System and point as reference. The below image shows the intersection

• Then we create two line using line command along the inclined walls of the intersection.
• Then a line is created by using two line and a point using Bisecting Line command. The image shows below is creating Intersection and Tooling Axis Along X Direction

Step 3 : Draft Analysis

• Draft anlaysis is done based on the tooling axis. Draft analysis is used to check the Class A is maintained with minimum draft angle of 3 degree.
• The Compass is used define the Draft direction.
• The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the surface. The image shows that draft analysis of the Class A surface with color scale variant.

Step 4 : Creating Class B Surface

• We first Offse the Class A surface with 2.5 mm which is given as thickness.
• Check for any discontinuity or gap between the joints or boundary is figured out in the offseted surface.
• If any any then by using Multiplr extract, Multi Sections Surface, Sweep are used to fill the gap.
• Thus the Class B surface is created. The image shown below is Class B Surface.

Step 5 : Creating Class C Surface

• The Class C surface is the connection between Class A and Class B surface.
• Then the boundary is extracted using Multiple Extract command or Boundary command.
• Then these extracted surface is Swept using Sweep command with reference surface option is used.
• Thus the Class C surface is created. The image shown below is Class B Surface.

Step 6 : Final trim to obtain Door Trim Plastic component

• The last step is triming the Class c surface with the Class B surface.
• Then the obtained surface is converted into solid using Close Surface and thus the final Door Trim Plastic Component is obtained. The image is shown below is Door Trim Plastic component

Step 7 : 4 - Way Locator Creation

• First we extract the surface where the Locator should positioned using Extract command.
• Then the Point is created in middle of the surface using Point command.
• Then the Plane is created with point using Plane command and Parallel through the Point with xz as reference plane.
• Then Sketch iscreated using the plane and the point using Positioned Sketch command.
• Then 4 - Way locator is created using Line command and it is Iso constrained by providing the proper dimensions.The image shown below is Sketch of 4 - Way Locator

• Similarly another 4 - Way Locator is created. The image shown below is Sketch of 4 - Way Locator

• Then the Sketch is paded using Pad command.
• Then the Draft angle with angle of 0.5 dgree using Draft command.
• Then the chamfer is provided at the edge for smooth fitting of locator using Chamfer command.
• Then the chamfer edge is fillet with radius 1 mm using Edge Fillet command.
• Then the other edges are filleted with radius 0.3 mm using Edge Fillet command.The below immage shows the 4 - Way Locator.
• Then the created 4 - Way Locator is Union Trimed with the Main Door Trim Body.
• Thus the 4 - Way Locator is createdThe below immage shows the 4 - Way Locator.

Step 8 : Heat Stakes Creation

• The Reference which is given in the Class A is taken as reference for creating the Sketch using Positioned Sketch.
• Then the heat stake sketch is creayed using circle command and then it is Iso Constrained by providing proper dimensions. The image shown below is Heat Stake Sketch

• Then the skecth is paded using Pad command.
• Then the Draft angle with angle of 0.5 degree is provided using Draft command.
• Then the Heat Stakes are transulated to 16 points using Translation command with Point to Point option.
• Then the created Heat Stake is Union Trimed with the Main Door Trim Body.
• Thus the Heat Stakes and Locator is created. The image shown below is Door Trim with Loactor and Heat Stakes.

Screenshots of the solid model:

Isometric:

Front View:

Side View:

Top View:

Draft Analysis of the Solid:

• Draft analysis is used to check the solid component is maintained with minimum draft angle of 0.5 degree for locator and heat stakes and minimum draft angle of 3 degree for Door trim.
• The Compass is used to define the Draft direction.
• The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the solid. The image shows that draft analysis of the solid with color scale variant.

Screenshots of the solid model with the proper color code of the draft angle in various orientations:

Isometric:

Front View:

Side View:

Top View:

Conclusion:

Thus the Door Trim Lower Plastic component through the given Class-A surface and also the Heat Stakes and the locators considering the design rules is created and the Draft analysi is also done.