Week 9 - Project - A pillar Design with Master Section

A pillar Design with Master Section

AIM:

• Create the Pillar, Plastic component through the given Class-A surface.
• To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

CLASS A SURFACE:

Class-A (or 'Strak') is a term used in specifically in automotive design. It describes the final production Class data for the aesthetic parts of the car. The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of Class modeling.

• Since we copy the Class A from the original Class A, then create separate geometric set then paste it. Then join the Class A.

TOOLING AXIS:

• Now we create tooling axis for the Class A. First a create axis system for where we want, then we create intersect based on the axis system.
• Extract the bottom surface and insert point on a surface then create lind based on a point.

MATERIAL USED IN DOOR TRIM:

ACRYLONITRILE BUTADIENE STYRENE(ABS) OR HIGH IMPACT RESIN:

High Rigidity:

• ABS has high rigidity and impact resistance. Even in low-temperature conditions or over long periods, ABS plastics will retain these characteristics.
• Its tensile strength is around 35-44 Mpa and because of its plastic yield at high strain rates, the impact failure of ABS is ductile rather than brittle.
• It is used in Instrument-Panel, Door-trims,Coin holder etc. As it has good impact resistance, it is used in creating bumpers as well.

Excellent Insulation:

• It has very good insulating properties, both acoustic and thermal.

Highly Weldable:

• It is a good weldable material as it is an amorphous material
• It is usually measured in terms of stiffness or modulus.

High Dimensional Stability:

• It remains mechanically strong over time.

Good Surface Characteristics:

• High Surface brightness and excellent surface finish. ABS is an ideal material whenever superlative surface quality, color fastness, and luster are required. ABS is a two-phase polymer blend.
• A continuous phase of ‘Styrene-Acrylonitrile’ co-polymer(SAN) gives the material rigidity. Hardness and heat resistance. The toughness of ABS is the result of microscopically fine polybutadiene rubber particles uniformly distributed in the SAN matrix.
• Hence, ABS is also used in Wheel-covers, IP substrate, etc

HIGH IMPACT RESIN:

• High Impact Polymer Resin is a Toyota Boshoku-developed resin material featuring the world’s top level of impact resistance.
• By controlling dispersion of PA11 (Polyamide) and PP (polypropylene) at the nanometer level, it forms a unique salami structure.
• Using High Impact Polymer Resin as an impact modifier, and performing high-expansion foam molding enables an approximately 20% weight reduction compared with conventional door trim materials, from 1.8kg/m² to 1.5kg/m².

CLASS A SURFACE:

The Class A Surface is given with the master section.

CLASS B SURFACE:

• Now create a class B surface.
• In class B, first create base of class B from class A. Insert geometrical set define as class B, that is base of class B.
• Use extract command and extract a base from class A. Then use untrim tool get full body of a base. Next use extrapolate tool extended a base , then offset of 2.5 mm.

CLASS C:

• Class C is nothing but its connecting part of Class A & B.
• Unhide the class A and take boundary of its and now boundary select the all corner of a class A and use sweep commends the we get a class c of boundary in Class A.
• Then trim it finally get class C.

CLASS C BOUNDARY:

CLASS C SWEEP:

CLASS A & C:

CLASS A B C:

CLOSE BODY:

• Go to the part body workbench then use close boby tool and finally get close body of A pillar.

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.

DRAFT ANALYSIS:

CONCLUSION:

Create the Pillar, Plastic component through the given Class-A surface.To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model is completed.