Week 9 - Project - A pillar Design with 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 the experience of the Structural design engineer.

Given Master Section as shown below:-

Tooling Axis Creation :

Creating Tooling axis for class A surface by extracting the bottom surface and creating a line with a point on the extracted surface.

We shall create Side core axis for creation of Dog House as shown below

DRAFT ANALYSIS OF CLASS A SURFACE

Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar. The surface is showing green colour so that the surface clears the minimum draft angle of 3 degree.

By using the analysis under the running point we can check draft angle on the individual faces. It shows how much draft on specific points when we move the cursor point

The given Class-A surface is continuos and we can proceed

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 offsetted surface we'll get the class B surface.

CLASS C SURFACE CREATION

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.

Let us do the final Trims with class A, Class B & Class C surfaces as follows :-

After Solidbody conversion Using close surface command in Part design workbench as follows :-

Let us carry on Draft analysis for the component :

Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar. The surface is showing green colour so that the surface clears the minimum draft angle of 3 degree.

By using the analysis under the running point we can check draft angle on the individual faces. It shows how much draft on specific points when we move the cursor point

In the above Image, draft is clearing for 3 deg

In the above Image, draft is clearing for 2.9 deg

In the above Image, draft is clearing for 2.6 deg

Let us create the Dog house with the help of given Master section :-

For Internal Rib design as per Master section

Converting all surfaces to solidbody and giving them draft along tooling direction, Dog house as follows :-

Let us carry on Draft analysis for the Dog house along the Side core axis :

Tree Structures as follows :-

B side features :-

Body Tree Structure as follows :-

Different Views are as follows :-

CONCLUSION

• Created the A-Pillar component using the given Class-A surface.
• The tooling axis for the given Class-A Surface is created which meeting the requirements of the draft angle.
• Draft analysis is done on the CLASS-A surface.
• Using the Close Surface feature, Solid body is created from the surface.
• B side Features are Creates as per Master section given
• Draft analysis is done on the Final Component.