Week 9 - Project - A pillar Design with Master Section

Aim: Week 9 - Project - A pillar Design with Master Section

Objective: The main objective of this challenge is to understand the given master section to create a solid body and B-side features for a given class A surface, by considering all the design parameters.

In Tree Structure

• Ensure using surface command.
• Use closed body command to create the solids
• Rename geometrical set properly.

Description: Master sections are the guides for design requirements which decide the component packaging after technical (Styling, Concept or Class-A) surfaces. Here in this challenge, created the solid part body from the class A surface and B-side features (Dog house) for the class A surface. The master section measurements are considered to make the solid part body and Dog house. Created a tooling axis by using the bisecting line method and created a side core axis for clearing the B-side feature of the dog house. The draft angle is provided to the dog house outer faces concerning the Tooling axis, and the draft angle to inside faces are provided concerning the side core axis. The draft angle for a solid part body is 3deg, the draft angle for the dog house's outer surface is 0.5deg, and the draft angle for the internal surface of the dog house is 0.5deg.

Tooling Axis creation:

To create the tooling axis, I used the xyz axis method. Initially, I created lines on the master section by using 'point to direction line' and then I created a coinciding line at the centre of lines from Dog house wall Master section

Point to-Direction lines on the master section:

Tooling axis:

Draft analysis for class A surface:

The craft analysis check is performed on the class A surface before we create the solid part from that class A surface, to check whether the given class A surface is drafted properly or not. The draft angle for a plastic component is 0deg to 3deg).

Class B surface creation:

To create the class B surface initially, measured the thickness of the master section (2.5mm). offset the class A surface 2.5mm to the inside direction. The styling fillets on the class A surface are not offset properly, it created the patch on the offset surface.used the sweep command to close the patch on the offset surface.

Offset patch:

extracted the edges of the patches, to give as a sweep command's guide curves to close the patch.

Class B surface:

Class C surface creation:

To order to create the class C surface, used the sweep command. sweep the class A surface edges along with referencing the surface for 4mm inside with 90deg. After the creation of the class C surface, the surface edges are needed to be extrapolated to intersect properly from all 4 sides.trim the surfaces which extrapolated, to get the closed class C surface. joined the class A surface and Class C surface to get a single surface of class A+C surfaces.trim the Class B surface with class A+C surface join, to get the closed surface to create the solid body.

class C surface:

class A+C join:

Solid part body creation:

To create the solid part body, used closed surface command in the part-workbench. gave the closed surface as an input in the closed surface command.

solid body:

Tree Structure:

Geometrical sets:

• Class A Surface Tooling Axis

• Class B Surface

• Class C Surface

• Class A+B+C Surface Closed Surface

• Dog House Design

• Ribs and Pocket Created

Part Body:

Free Form Analysis (Draft analysis) & Publications:

Dog House creation:

• To create the dog house on the B-side, extracted the lines on the master section and I create a plane to extract the lines concerning the master section.
• extracted the faces which are required to create the shell for the dog house, and trim the surfaces with each other as per the master section dimensions.

Dog house outer shell:

• To create the dog house on the B-side, extracted the lines on the master section and create a plane to extract the lines concerning the master section.
• extracted the faces which are required to create the shell for the dog house, and I trim the surfaces with each other as per the master section dimensions.
• created the side core access, by creating a line at the centre of the back surface by creating the point.
• thicken the shell for mm to inside. After thickening the surface, gave deg draft to inner surfaces of the dog house.
• adding the dog house to the main part body of A pillar solid.Solid part body of A pillar with Dog house:

Dog house top cutout sketch:

Dog house:

• added the dog house to the main part body of A pillar solid.

Solid part body of A pillar with Dog house:

Draft analysis for the solid part body:

The draft analysis is used to check the surface draft angel and to know whether all the surfaces are drafted properly or not.

• The draft angle for the solid body of A pillar is 3deg, some surfaces are not cleared properly with a 3deg draft angle.

3deg draft angle:

Draft analysis for dog house outer surface:

Draft analysis for the inner surface of the Dog house:

Different views:

Isometric view:

Front view:

Right side view:

Top view:

CATpart in the attachment as Zip

Conclusion :

In This Project A pillar Design with Master Section the A Trim & The dog house for the A trim was created by considering the design rules, and the Draft analysis performed on the final component is successfully done.