Week 9 - Project - A pillar Design with Master Section

DESIGNING A PILLAR USING MASTER SECTION

OBJECTIVES

• To improvise the Class A surface by resolving bad patches and adding flanges to it.
• To create A pillar solid model with the help of improvised class A surface.
• To create B side features for the A Pillar using the master section given to us as an input.
• To create main and side core tooling axis for A pillar and its B side features.
• To do the draft analysis of the overall model of the A pillar i.e including B side features.

INTRODUCTION

MASTER SECTION: Master sections development takes place during feasibility check and concept validation stages of the product life cycle. These are typically the guides for design requirements and which decides the component packaging after the development of the concept design, i.e class A surfaces.

Master section helps us to decide the feasibility of the concept design, the clearances, the packaging and the fixation strategy of a component before converting the concept design into a solid 3D engineering design.

During the period of vehicle concept design the evaluation of the master section performance depends mainly on the reference vehicle data and experience of structure design engineer.

CREATION OF MAIN AND SIDE CORE TOOLING AXIS

Apart from A surface and C surfaces we also need to consider the B side attachment features in order to create the tooling axis because all the attachment features have a large number of surfaces parallel to the tooling direction.

For creating the tooling we can take reference from the master sections of the B side features and create tooling axis accordingly as shown in the figures below.

CLASS B SURFACE CREATION

We need a thickness of 2.5mm for the A PILLAR so in order to create the class B surface we'll give an offset value of 2.5 mm to improvised class A surface.

After applying the offset command we'll see some of the patches of the resulting surface are not generating so we have to recreate those patches by using multi-section surface command.

On joining the recreated patches with the offseted surface we'll get the class B surface.

CLASS C SURFACE CREATION

Extract the side edges, front edges and rear edges of the improved class A surface and use sweep command using "with refrence to draft" option and make the draft angle equal to 3 degrees.

For the rest of the edges use multi-section surfaces command to make surfaces inline with the major surfaces created through sweep.

Join all the surfaces together using join command.

JOIN CLASS-A AND CLASS-C

SOLID BODY CREATION OF THE A PILLAR

Using the Trim command join the class A surface with class C surface.

Trim the resulting Trimmed surface with class C surface.

The resulting trim we'll get is the closed shell body of A pillar.

Finally use closed surface command in the part design workbench which would lead the shell body into a part body.

CREATING DOG HOUSE

There are some of the attachment features like doghouse that needed a side core during moulding operation so for such B side features we have to create a side core tooling axis.

For the creation of side core tooling axis again we can take refrences from the master sections of the A pillar. This is shown in the figures below.

Draft Analysis

Draft analysis for side core axis.

Boolen operation

Join both the part with the help of Boolen operation using union trim and trim the part which is not required.

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Tree Diagram