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.

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.

Procedure for Tooling axis creation

• Check the best possible tooling direction by manually adjusting the compass.
• By analysing it is found that y axis as tooling direction would clear most of the faces without any difficulties.
• Now extract any surface and create a mid-point on it.
• Then create a dummy axis creating a line on the point and direction along the y axis.
• Perform draft analysis to find whether the given axis clearing the draft analysis. If not create a new tooling axis.

Draft Analysis :

1. The part created has to be changed to the material modes in the display frame.
2. Compass is enabled aligned light along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft and angles

Draft analysis for Class-A surface :

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.

Extended B Surface for Trimming

CLASS-C surface creation

Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled

• Create the sweep surfaces with reference to surface and tooling axis by multi extracting the CLASS-A boundary
• Join the sweep surfaces by using commands like extrapolate, trim, multi section surface.
• Finally join all the sweep surfaces and ensure the continuity of the CLASS-C surface.

A and C Joining

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.

Make a solid part body using the close surface command in the part design workbench

Dog House Creation Using Master Section

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.

Conclusion :

Hence the Master Section for the considering the design rules for rib creation and Dog House creation and Draft analysis is also performed for the final component is successfully done.