Week 9 - Project - A pillar Design with Master Section

AIM-Week 9 - Project - A pillar Design with Master Section

Draft Analysis ?

The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line.

Draft angles ?

Draft angles are very important in thermoforming product design. If the product is formed onto a female or negative mold, it shrinks away from the mold sidewalls. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles. If the product is formed onto a male or positive mold, it shrinks onto the mold sidewalls. A draft angle of 1–5 degrees is recommended for all male or positive products.

here we are taking minimum 7degree of draft angle because our die should not get damage and we should get a finish good product. In some area we cannot avoid negative draft. So bending operation is provided for the manufacturing process, because deep drawing cannot be done at the negative draft area.

Tooling Direction for Plastic Part

Tooling direction is main consideration for plastic part and mold parts because it defines movement of mold part and possibility of plastic part to come-out from mold part (Core and Cavity).

Tooling Direction:-

In Molding machine arrangement is given to open the mold along a direction which is known as Tooling Direction.

In other words. The mold is built from two separate halves (Core and Cavity) and tooling direction basically define the direction of mold pulls apart.

Tooling direction is known as primary direction.

WHAT IS CLASS A, B, C SURFACES ?

Class A:- Styling or A class surface are the terms used in plastic product design. That means the surface of a component that is smooth (aesthetic) or visible side to the human eye after the part is assembled.

Class B:- It is an engineering surface, and it gives you thickness from class A surface

Class C:- when Class A and Class B surfaces are joined along the tooling axis it is called class C surface.

WHAT IS 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. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity. Dog house and other engineering components are built on B-surface.

CONDITION FO DOG HOUSE

"C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• The height of ( B ) should be between 3.0 – 6.0 mm

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FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .

THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.

FOR CLASS B SURFACE USE THE OFFSET COMMAND. THE OFFSET IS DONE AT 2.5MM

SOME PATACHES CAN BE SEEN THIS PATCHES CAN BE REMOVED BY

WHEN WE HAVE 2 DIFFERENT SURFACE SO FOR THAT I HAD EXTRACTED THE BOUNDRY AND THEN TRIM TO REQUIRED PORTION.

BUT HERE WE ARE USING SWEEP COMAND TO RECOVER THE PATCH.

THIS IS THE CLASS C SURFACE WHICH IS SWEEP FROM THE CLASS A SURFACE WITH THE TOOLING DIRECTION SOME PLACES USED WITH RESPECTIVE TO SURFACE ALSO.

{ BOUNDRY- SMOOTCURVE-SWEEP}.

AFTER EXTtending burface and c surface will trim ALL OF THEM TO CRERATE CLOSE BODY.

THIS IS HOW CLASS A AND CLASS C SURFACE LOOK WHEN JOIN.

TO CHECK WETHER THIS SURFACE IS FULLY JOIN USE BOUNDRY COMAND WHEN IT SHOWS THIS MESSAGE MEANS IT IS CLOSED SURFACE.

FOR CREATING DOG HOUSE I HAD EXTRACTED THE MASTER SECTION THEN EXTEND COMAND AND CRREATED CLOSE BODY OF THE DOG HOUSE .

SAME TOOLING DIRECTION WILL BE USED .

NO NEED TO PROVIDE DRAFT BECAUSE THE MASTER SECTION IS IN HAVING THE DRAFT.

SAME METHOD IS USED FOR THE INNER RIB OF THE DOG HOUSE.

USED EXTRACT THE SURFACE OFSET IT TO 1MM. THEN USE TRIM OPTION OF THE SKETCHER WORK BENCH.

FINALLY USED THE UNITRIM COMMAND TO REMOVE UNWANTED MATERIAL AND GET FINAL PRODUCT.

DRAFT ANALYSIS

THE FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE

DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.

• DRAFT ANALYSIS IS DONE ON FINAL BODY FOR NOW IGNORE THE DOG HOUSE BECAUSE DOGHOUSE IS WILL HAVE LESS DRAFT DEGREE.
• DRAFT ANALYSIS IS DONE ON THE SOLID BODY HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE.
• THE BLUE COLOR MEANS THE DRAFT ANGLE IS NEGATIVE DEGEE WHICH IS MANDATORY FOR THE SOLID BODY BASE SIDE.
• THERE ARE SOME RED PORTION WHICH IS ON A SURFACE THE A WHICH WILL COME AT SOME PORTION.
• RED LINES ARE OF FILLETS WHICH IS ACCEPTABLE.
• WHEN THE DRAFT ANGLE IS 2.9 SOME OF THE ARE GETS GREEN WHICH IS ACCEPTABLE.
• THE RED COLOR IS COMING BECAUSE IT IS VERTICAL PORTION.

THE DRAFT ANALYSIS FOT THE DOG DOUSE IS GIVEN 1.5 MM.

IT LOOKS LIKE THE IT IS NOT CLEARING DRAFT ANALYSIS BUT IT IS COMPLEATELY CLEARING .

NOTE, TOOLING DIRECTION MOVES FROM TOP TO BOTTOM AND THEN BOTTOM TO TOP.

SO, IN ONE DIRECTION IT IS CLEARING HALF AND IN OTHER DIRECION IT IS CLEARING OTHER HALF.

HER FOR THE INNER PART DIFFEREN TOOLING AXES IS TAKEN WHICH IS HORIZONTAL TO THE DOG HOUSE.

THE DRAFT ANALYSIS FOT THE DOG DOUSE IS GIVEN 0.45 MM.

IT LOOKS LIKE THE IT IS NOT CLEARING DRAFT ANALYSIS BUT IT IS COMPLEATELY CLEARING .

NOTE,

TOOLING DIRECTION MOVES FROM TOP TO BOTTOM AND THEN BOTTOM TO TOP.

SO, IN ONE DIRECTION IT IS CLEARING HALF AND IN OTHER DIRECION IT IS CLEARING OTHER HALF.

FINAL BODY

TREE STRUCTURE

FULLY CONSTRAIN

THANK YOU