Week 9 - Project - A pillar Design with Master Section

Aim: To Create the A pillar through the given Class-A surface and master section by creating a required tooling axis.

Objective:

• To create a class A and Class B surface using given surface and mastersection.
• To create the dog house and attach to the A pillar.
• Perform Draft analysis on the compenent.
• Create solid usig close command.

Procedure for Designing A pillar:

To start with is to download and open the below class A file of the A pillar.

Now check the continuity of the surfaces using boundary option. There should not be not gao between the surfaces.

Tooling Axis / Direction creation:

Once it is verified that there is no gap, next step is to create Tooling axis of the above model. Check visually for the direction of tooling. The should be permissible 3 degree approx. draft angle for the ejection of the part after manufacturing.

For that should create a dummy axis in any direction.

The base of the class A surface is extracted and a point at the center is created and axis system is inserted.

Create side core axis for the dog house also in a similar way.

As the tooling axis is created next publish it using publication option in tools section.

First thing we have to do is to extract the base surface using extract tool .

Next offset the surface by 2.5mm.

Since few surface are unable to offset, it means that there is a problem or flaw in the A surface provided.

• Delete all the extracted surfaces.
• Now click Join command and select the class A surafce
• Now select the "Sub-elements to remove" tab and select the elements which were not offsetting.

• Next extraxt the boundary as shown below to perform sweep operation.

Select the propagation type as "Tangent continuity".

Now click sweep commant select the curve extracted and guide and click ok.

Now join the surfaces and finally the class A surface is created.

Creation of Class B surface:

Offsect the class A surafce to 2.5mm.

Class B surface is created.

Class C Creation:

Create the boundary of the class A first into parts we cant create the class c surface in one go.

We have to perform multiple section surface, sweeps and trim them and join together as shown below.

Now trim the surafce and the class C surface is created.

Now join the Trimmed surface with the class A / B surface.

Now check for the boundary if open edges are there or not.

Since there is no open edges, we can proceed to creating solid.

Open part design workbench and click close surface , select the surface body and click ok.

Now the solid is created.

Steps for Draft Analysis:

Change the view mode to the custom view and select view paramater as Material mode, then the draft analysis is enalbles.

Click the draft analysis option , move the compass with the red dot to align with the tool axis.

Now lock the compass and click anywhere on the part, the color will be changed.

Change the value of the green color limit as required.

The green color shows that the surface satisfies the draft angle and other color if the angle is not satisfied. This can be corrected by altering the angle and measuring at points to get succesfully draft to get satisfied.

If the red colour appears further even after the change in the max. and min. draft angle, that means the class A surafe is not 100 percent perfect. Its further sent to the feasibility check and to the engineers to verify it.

Creation of Dog House:

The below image show the dimensions of the dog house.

With the help of this image and master section, the whole Dog House attachment is created.

First create a point and plane as shown below.

Draw a sketch as per the dimensions.

Extrude the sketch and convert it to solid by using thick surface option

Create the ribs as per the given dimensions and appropriate thickness.

Perfrom union trim operation to remove the excess rib from the main dog house body.

Create surface at the bottom and using split command, split the body as below.

Draft the inside surfaces of the ribs for 0.5 degree.

Now we have to create the slot at the top surface.

Now again split the body using the extruded surface.

Now apply fillet to the appropriate edges and Attach the dog house to the A pillar using union trim.