Week 9 - Project - A pillar Design with Master Section

Project - A pillar Design with Master Section

Aim:

To Create the Door trim lower component through the given Class-A surface & to design engineering features such as Dog House With Ribs inside.

Take the Thickness of the component as shown in the master section to be 2.5 mm.

INTRODUCTION:

CLASS-A SURFACE: A surface made by the designer which is given as input to the plastic modeler to work on. It is an aesthetic surface
and the outermost surface.

CLASS-B SURFACE: A surface below a certain thickness from the class-A surface is a class-B surface. This is the surface that contains
engineering aspects of a model.

CLASS-C SURFACE: A surface that joins class-A and class-B surfaces is a class-C surface.

Methodology :

In this design we will focus on the following steps

1. Tooling Axis
2. Draft Analysis
3. Class B Surface
4. Class C Surface
5. Making a solid model from Class A surface

Following tools were used to reach the final Solid Model :

1. Extract
2. Un - trim
3. Trim
4. Offset
5. Extrapolate
6. Boundary
7. Edge Fillet
8. Sweep
9. Join
10. Close Surface ( Part Design )

TOOLING AXIS

Tooling Axis 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).

• 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.

There are two methods to create Tooling Axis -

• Bisecting method &
• Inertia method

For this Component Tooling Axis is created by Bisecting method -

• By taking Extract of the base and creating a point on centre of the extact and then creating axis system or plane on that point .
• Intersecting the Class A with the point .
• Creating bisecting line using the extracts on the intersection .
• Checking the tooling axis created is clearing all the sides of the Class A by keeping it in Normal view mode.

FOR CLASS B SURFACE :

1. Invisible Surfaces.
2. Surface mostly don't have textures
3. Surface needs to be created according to the class-A surface.
4. Having all features in B-side surface only.
5. Surfaces which is having TANGENT CONTINUITY IS CALLED class-B

Just Offseted the Class A for 2.5 mm & performed some modifications as per requirement.

FOR CLASS C SURFACE:

Took boundries for class A in some sections and in other sections took Multiple extract for Class A Surface.

Sweept using boundries and Multiple Extract with Reference surface.

CLASS A CLASS C TRIM

Final Trim -

Class A + Class B + Class C

Closed Body -

For Creating Dog house -

• Design Rules for 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

Sketches-

Dog House Solid Mold-

DRAFT ANALYSIS :

Class A surface draft analysis -

The above image shows the draft analysis in which green color surfaces shows that they are having an angle of more than 3 degrees but the surface in red color shows it is less than 3 degree. These are the results of the draft analysis which are very crucial for determining the feasibility of the product

Solid component draft analysis :

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour range identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values. After draft analysis done we can observe that the green colour shows that the drafted walls of the switch bezel are above 3 degrees which is a permissible criteria to manufacture in injection moulding.

Draft Analysis For Dog House -

Draft Analysis. For Final Part-

• Draft analysis is done on the final part with the tooling axis as reference
• Green surface indicates the areas where the draft is more than 0.5 degrees.
• Red surface indicates the area having negative draft.

SOLID MOULD :-

TREE STRUCTURE :

CONCLUSION:

• The Tooling axis and the SolidCAT part with B side feature is created from the given Class A Surface and Master Section & Draft Analysis is Performed.