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

Initially, we need to offset the given Door Trim class A surface in the inner direction to the required thickness (here the thickness is 2.5mm). After that, we need to close the patches on the offset surface of the bumper, the patches are formed due to the fillets on the Class A surface. Once all the patches are closed properly join them together to make a proper class B surface and now sweep the boundary of the class A surface to trim with the class B surface to make a closed body. By using the closed body command in the Prat workbench we can get the solid body from the closed surface of the Door Trim. Now, I created the Heat stakes and Locators by considering all the design parameters. After creating all the B-side features on the solid part body of the door trim, I performed a draft analysis for it to check whether all the surfaces are drafted properly or not (The draft angle for the plastic component is 0.5deg to 3deg).

TOOLING AXIS:

To create the tooling axis, I extracted a surface from class A and created a point in the middle of the surface by using the point command and created a line at that point through the x-axis. Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not. If in the draft, analysis check the surface highlighted with green colour on both sides of the surface the tooling axis is in the correct position and direction.

DRAFT ANALYSIS OF CLASS A SURFACE :-

CLASS B SURFACE:

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 2.5mm, so I offset the class A to 2.5mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multiple extract and extrapolate command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface.

CLASS C SURFACE:

I used the sweep command to create the class C surface concerning the boundary of the class A surface. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweeped surfaces until both surfaces got intersect properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the centre hole of the door trim. Now, join both class A and sweep boundary to get the complete class C surface.

PART BODY:

To create the solid part body from the closed surface, I used the closed surface command in the part workbench.

CREATION OF LOCATORS:

To create the locators, I created a sketch on the body. After creating the sketch, I pad it 20mm in height and thicken it to 1.3mm and I drafted it with 0.5deg in the direction of the tooling axis. I gave 5mm of chamfer with 45deg of inclination and after I gave a fillet of 0.25mm radius.

4-way locator:

CREATION OF HEAT STAKES:

To create the heat stakes, I draw a sketch on the surface. After the creation of the sketch, I pad it to 18mm height and I gave a draft angle of 0.5deg on both sides (inside and outside) and then I gave a fillet with a 0.25mm radius. After creating the heat stake, I created the ribs for supporting purposes. To create the ribs, I draw a sketch and padded it to 12mm in height and 1mm in thickness. After padding the ribs, I drafted 0.5deg in the tooling asix direction and filleted it with a 0.25mm radius. Finally, I union trim the ribs with a heat stake to remove the ribs, which are present inside the heat stakes.

After creating the heat stake I created a copy and created a paste special command to get the link with the result and with the help of point to point translate command i PLACED ALL THE HEAT STAKE IN THEIR RESPECTIVE PLACES AS GIVEN IN THE REFERENCE POINTS.

CREATION OF RIBS:

Ribs are a feature in plastic injection molded parts. They are thin extensions that run perpendicular from a wall or plane. They are commonly used to provide additional support and strength to a part. Thickness and location are essential to rib design.

To create the ribs, I draw a sketch and padded it to 12mm in height and 1mm in thickness. After padding the ribs, I drafted 0.5deg in the tooling asix direction and filleted it with a 0.25mm radius.

use power copy to produce rib and another two ribs are produce using tranlate command to have command on both the steps.

CREATION OF DOG HOUSE:

Dog house is an engineering feature used in plastic trim design. Dog houses are used as supporting feature. Sometimes other engineering features like snaps; locators etc. are mounded on them to increase their strength.

• To create the Dog house, I draw a sketch and padded it to 18mm in height .
• After padding in the direction of tooling axis, I drafted 3deg in the tooling axis direction and filleted it with a 3mm radius.
• Than i remove the material from the base of it having a thickness of 0.4*T=1 mm.
• Than provide draft it to 0.5degree in the direction of side core axis.
• Then shell the main padded structure to 0.7*T=1.75mm.
• Remove the second bbody from the first body .
• After joining both the bodies translate it to required points and rotate it with respect to its edge .

VARIOUS VIEWS :-

DRAFT ANALYSIS OF PART BODY :-

1) DRAFT FOR 3 DEG ANALYSIS

2) DRAFT FOR 0.48 DEG ANALYSIS :-

TREE EXPANSION :-