Week 9 - Project - A pillar Design with Master Section

A-PILLAR DESIGN WITH MASTER SECTION
This report demonstrates the complete design of an Automotive Plastic Component –A-pillar Design with Master Section from a given Class-A surface and master section as an input.

Note:

The component is designed using CATIA P3 V5-6R2021

OBJECTIVE
The aim of this Project is to create the Plastic component A-PILLAR DESIGN WITH MASTER SECTION from given Class-A surface with master section along with creation of TOOLING AXIS. In the end DRAFT ANALYSIS for CLASS-A along with the closed bodyhas also been performed.

INTRODUCTION

TOOLING AXIS:

The line along which the mold (CORE and CAVITY) opens. It decides the direction of two mold half opening or closing. The component should clear the tooling axis in the given specific direction. As a general rule, along tooling axis we must we able to see maximum faces of the component.

There are different methods to create tooling axis. It depends on

• The given surface geometry (face symmetry, surface normal, assembly direction etc)
• Already given direction in input (by customer)

In this case a line normal to the surface gives the best possible direction of tooling axis. Hence a line drawn normal to the base of A-pillar will be our tooling axis.

DRAFT ANALYSIS:

It is a tool that allows the designer to check in advance whether the part they are designing can be removed easily from the mold being used to make it. A functional part for injection molding must have draft angles that face both the cavity and core sides. This will reduce the risk of damage to the parts and ensure that part can be ejected from the mold easily. When the draft angle is provided the sticking tendency of the part during removal becomes minimum because as the part ejects contact between surfaces breaks which leads to the reduction in friction and easy removal of the component.Generally a 3 degrees draft angle is recommended on the surfaces, 0.5o on ribs and 1.5o on dog house. In CATIA before doing draft analysis first change view mode as material.

PUBLICATON:
Publication is used for easy access of the surfaces or components to work or view them.

PROCEDURE TO CREATE THE TOOLING AXIS
If the component is symmetric about one or more plane then bisection method is best suitable. But in this case a line normal to base is the easiest and best possible way to create tooling axis. Second tooling axis has been created for draft analysis of dog house.

CREATION OF CLASS-B SURFACE
By using extract, offset, and sweep features; class-B has been created. It has an offset of 2.5mm from class-A.

CREATION OF CLASS-C SURFACE
By using multiple extract, sweep, extrapolate and trim features class-C has been created.

CREATION OF CLOSED SURFACE
By using trim feature closed surface has been created.

CREATION OF CLOSED BODY
By using insert body and close surface feature closed body has been created.

DESIGN OF DOG HOUSE

SKETCH SOLVER STATUS
The edges has been directly projected from the master section.