Week 9 - Project_1 - Door Trim Lower with Engineering Features

DOOR TRIM- HEAT STAKES &LOCATORS

DOOR TRIM -

I got the class a surface then I created boundary to check the surface that is fine for creating class b surface, c surface and close surface.

TOOLLING AXIS – I created the tooling axis by using normal to surface method. I extracted a surface and created the point on surface method and give the value zero. I created the line by using point-direction method and give the direction as y component. At last I named it as tooling line. Tooling line is the tooling axis for my class a surface.

FEATURE DRAFT ANALYSIS 1 – When I got the tooling line then I go for give draft analysis. I clicked on feature draft analysis and pick the surface In material mode and pick the compass on tooling line and pick the class a surface also I had given the draft angle 2.9 degree. After picking the class a surface its showing in fully green colour and when I changed the draft direction the it`s showing fully blue colour. Now I assured that my tooling line is correct for class a surface. Now I can go for other operations.

CLASS B SURACE – I offset the class a surface by 2.5mm which is the thickness of my component. After offsetting I extracted it by using multiple extract in four parts with no propagation, multiple extract 1, multiple extract 2, multiple extract 3, multiple extract 4. Because all four surfaces had some gap.

Step 1 – In multiple extract 4 had some issue in surface offsetting there had one surface not come in offset so I take three inner boundary of that area then I created the spline using the outer edges of that particular surface and after that I created the multiple-section surface and give the deviation as 0.01mm to gain the surface. After doing that I joined it with multiple extract 4 and give the merging distance 0.01(earlier I gave the deviation as 0.01 so I have to give the merging distance 0.01 to do join operation) and I got a full surface.

Step 2 – I created the boundary of multiple extract 1 and extrapolated it by 13mm with curvature continuity and propagation mode as none.

Step – In this step I took the outer edges of multiple extract 2 and extrapolated by 13mm with curvature continuity and give the propagation mode as point continuity.

Step 3 – In this step I took boundary of outer edges of multiple extract 3 and extrapolated it by 19mm with curvature continuity and no propagation mode.

Step 4 – In this step took the boundary of join 1 which was closer to extrapolate 1 and extrapolate it by 19mm with curvature continuity. After that I took the boundary of outer edges of extrapolate 4 which was closer to extrapolate 2 and extrapolate it by 2.5mm with curvature continuity. After that took the boundary of outer edges of extrapolate 6 which was closer to multiple extract 3 and extrapolate it by 12mm with curvature continuity. After that I pick the small edge of extrapolate 6 which was nearest to all three extracted (multiple extract 1,2, and 3) and extrapolate it by 15mm with curvature continuity.

Step 5 – In this step trimmed all four extrapolate and got the surface. After that I created a geometry set FILLETS MEASURE. In this geometry I extracted the three filleted surfaces and then I untrimmed them. After I created the point on curve and then I created a circle by three point method. After that for other two surfaces I done the same as with first then I measured the radius of all three circles.

Step 6 – After measuring the fillets value I done the three edge fillet. In first and second are the same value near to 1.5mm so gave them 1.5mm. in third one had 6.91mm so gave it 7mm and created the fillet.

Step 7 – In this step I took the lower edges of edge fillet 2 as boundary and extrapolated it by 12mm with curvature continuity and no propagation mode. After that I took the second outer edges of extrapolate 12 as boundary and extrapolate it by 0.5mm with curvature continuity and no propagation mode. At last I named it as class b surface.

CLASS C SURFACE –

Step 1 – For class c surface I took the lower outer edges of class a surface then I created boundary. After that I created sweep surface with line command subtype as with reference surface and give the guide curve as boundary 10 and for reference surface I pick the class a surface also for angle value give 90 degree and length 10mm.

Step 2 – In this step I took the outer edges of hole surface as multiple extract and propagation type as point continuity. After that I created sweep surface in line command subtype as with reference surface and guide curve as multiple extract5 for reference surface I pick the class a surface and angle value 90 degree and length value 10mm after that I named it as c surface 1.

Step 3 – In this step I took the second outer edges of class a surface as boundary. After that I created sweep surface with line command and subtype as with reference surface and guide curve as boundary 11 and angle value 93 degree and length value 5mm sweep surface.

Step 4 – In this step I extrapolate the lower edge of sweep 3 and then I extrapolate the another lower edge of extrapolate 8 with 5mm. After that I extrapolate the sweep 1 edge by 5mm with curvature continuity then I extrapolate another surface same as before. After extrapolate all those surfaces I trimmed the extrapolate 9 with extrapolate 11 and named it as class c surface 2.

CLOSE SURFACE AND CLOSE BODY – In this stage I joined the class a surface with class c surface 1 and 2. After join operation I trimmed it with class b surface then I got a close surface. Before go for close surface I have to check the boundary of that close surface and it shows as that it can`t be formed, now I assured that my close surface is perfect for close body operation so I go to part design and select close surface command and pick the trim3 then I got the close body.

HEAT STAKES AND LOCATORS –

LOCATORS – 1 – 4 WAY LOCATORS – For 4 way locators I extracted the b surface by multiple extract command with point continuity and then created a point and then created a ZX plane after that I created a position sketch and insert a body named it as 4 way locator then I pad it pick the thick option for length of the locator I gave 13mm then I draft it by 0.5degree.After that I gave the chamfer of 3mm and then I gave 1mm edge fillet and 0.3mm for rest surfaces. After that I copy it and paste special as result with link and then translate it x direction 600mm and y direction 20mm.

2 – 2 WAY LOCATOR – For 2 way locator I crated a position sketch and then I insert a body named it as 2 way locator and then I pad it pick the thick option for length of the locator I gave 13mm then I draft it by 0.5degree.After that I gave the chamfer of 3mm and then I gave 1mm edge fillet and 0.3mm for rest surfaces.

HEAT STAKES – For heat stakes I created a sketch using ZX plane and pick the point 21 for projection point. After that I pad it lower 5 mm from locators because our locator were fix first then heat stakes. After that I gave the draft of 0.5 degree. After that I copied it and paste special as result with link for 15 times and then I named them by serial number. After that I pick the translation command and translate them one by one by point to point translation method.

APPLIQUE – After creating locators and heat stake I inserted a body and named it as heat stake assembly and assemble all heat stake. After that I insert another body and named it applique and then assemble locators and heat stake assembly.

COUNTER PART CLEARANCE –

1 – For counterpart clearance I inserted a geometry set and named it counterpart clearance and then copied the sketch 1 and pate it. After that I reconstructed the sketch and created a circle by 15.2mm which is the 0.1 clearance par side and make the previous sketch construction element and then pad it same as 4 way locator and then I gave the draft 0.5degree. After that I insert another body and translate by point to point method. After that I copied the sketch 2 and paste it in counterpart clearance and then I reconstructed the sketch and created a circle by 15.2mm which is the 0.1 clearance par side and make the previous sketch construction element and then pad it same as 2 way locator and then I gave the draft 0.5degree. After that I copied the sketch 3 and pate it counterpart clearance and then reconstructed the sketch I deleted the 5mm diameter circle and for 7mm circle I make it 8mm, there 0.5mm clearance per side. After that I pad it as previous heat stake feature and gave the draft of 0.5degree. after that I copied the heat stake clearance and paste special as result with link 15 times and pick the translation command by point to point method I translated all 15 bodies and then I inserted a body named it as heat stake clearance assembly and then assembled all the heat stake clearance. After that I done the Boolean operation, first I removed the locators clearance and heat stake clearance assembly then I added the locators and heat stake assembly to the main part body.

FEATURE DRAFT ANALYSIS 2 – For second draft analysis I took the feature draft analysis command and then pick the compass on tooling line then pick the part body and gave draft angle 0.45 degree, now I can see that my all locators and heat stakes are clearing the tooling axis.

NOTE – For class c surface 2 there are some surface in draft analysis shows in red colour because there are a surface perpendicular with class a surface so that individual surface I gave the draft angle 3 degree additional that is the reason it shows in red color.