Challenge

A pillar Design with Master Section

OBJECTIVE

To design the A PILLAR Plastic component using the given Class-A surface and master section with a thickness (T) of 2.5mm.
To create the Dog House considering the master section design and rules mentioned.
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

PROCEDURE

1. Defining a Tooling axis for the Class-A surface

Step 1: Check the connectivity of the surface and ensure there is no gap in the class A surface. The boundary command helps by highlighting the boundary of all the edges thus we can visually check for gaps in the class A surface.
Step 2: We extract the plane surface and create a point in the middle of the surface. we also create lines on the master section of the dog house side walls.
Step 3: Next we create a bisecting line through the point. This is the main tooling axis.
Step 4: We perform a draft analysis on class A and check the angles of the surface we think will create problems in tooling.

2. Creating Class B surface

Step 1: We offset the Class A surface to 2.5 mm towards the back of class A.
Step 2:We observe a discontinuity in the offset surface.
Step 3: We extract the boundaries and create a sweep with reference surface without giving the surface as the support and the long edge as the guide curve. We join the sweep with the offset surface.
Step 4: We extrapolate the above surface by a few mm on all the edges to get the final B surface.

3. Creating Class C surface

Step 1: We use the boundary command to extract the side edge boundaries into 4 different boundaries and use sweep with reference surface to create a surface at 90 degrees or 93 degrees where it needs clearing for 6 mm.
Step 2: We extrapolate the ends of the above surface and trim all 4 sweeps together to create the final C surface.

4. Creating the hollow surface part

Step 1: We use the join operation to join the Class A, and C surfaces and trim them with Class B surface into one body to get the final surface body.

5. Publication of the Tooling axis, Class A, B, and C surfaces

Step 1: We select the tooling axis, dog house side tooling axis, class A, B, and C surface from the tree and go to Tools->Publication to publish them.

6. Creating the final solid component

Step 1: We switch to the part design workbench and use the Closesurface feature to create the solid part out of the hollow surface body.

7. Creating the Dog house

Step 1: We create a plane through 3 different points of the doghouse master section.
Step 2: We create a positioned sketch and project the outer edge of the dog house master section and isolate them. we constrain them fully and create the pad for 20 and 10mm.
Step 3: We shell the front and bottom surface for 2.5mm.
Step 4: We create a line normal to the above plane. This is the side core axis.
Step 5: We draft the inside surfaces for 0.5 degrees along the side core axis.
Step 6: For the coring, we extract the inside surface and offset it for 0.6T (1.5mm). We also offset the base extract for 3-6mm and trim together to get the coring snipping surface.
Step 7: In the part workbench, we snip the doghouse by the above surface to get the coring.
Step 8: We draft the inside surfaces along the side core axis for 0.5 degrees and edge fillet to get the final dog house canopy.
Step 9: We create another sketch for the locator's ribs. We pad and thicken it with a thickness of 1 mm and create edge fillets and union trim with the dog house canopy.
Step 10: We create another plane at 90 degrees from the previous plane and create a sketch for the cutout.
Step 11: We pad the sketch and remove it from the dog house to get the final dog house.

all views

8. Draft analysis

Step 1: We open the draft analysis command box, select the compass, drag, align it with the tooling axis, and lock it.
Step 2: We analyze the color scale, input the required draft value and save the analysis.

TREE STRUCTURE