Challenge

Week 9 - Project - A pillar Design with Master Section

DDinesh T1 Dec 2022

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.

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.

MASTER SECTIION

REFERENCE FOR CLASS A, CLASS B & CLASS C SURFACE.

CLASS A SURFACE ;

check the surface quality

check the any patches available in surface with boundary

let's join the surface

DESIGNING METHODOLOGY:

IMPROVING THE CLASS A SURFACE

The given class A surface is not a proper surface because it is lacking the side flanges so first thing that we have to do is to create the flanges on both the sides of the class A surface.

For creating flanges we will first extract the side edges of A surface and the surfaces touching these edges.

Finally we'll apply the sweep command using the "with reference to the surface" option and join the resulting edges with A surface using trim command.

Make sure that the resulting flanges are properly oriented according to the master section

TOOLING AXIS

create the two lines with the master section, bisecting the line & create the tooling axis.

DRAFT ANALAYSIS

Draft analysis for class A surface

CLASS B SURFACE CREATION;

Create B surface offset form the class A surface as per master section.

missing surfaces create with swept surface.

let's join the surfaces & create the class B surface

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 ;

create the surface with swept & multi section surfaces.

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.

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.