Week 9 - Project - A pillar Design with Master Section

Design overview,

1)Create tooling axis.

2)Create Class B surface.

3)Create Class C surface.

4)Create solid model.

5)Create dog house.

6)Perform draft analysis.

Tooling axis

1) In order to create the tooling axis because all the attachment features have a large number of surfaces parallel to the tooling direction.

2)For creating the tooling we can take reference from the master section of the B side features and create tooling axis.

3)It is created by bisecting the lines from the master section and it is formed.

4)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.

5)For this,we are taking reference from the master section and it is created.

Side core tooling axis

Class B surface

1)It is performed by offsetting the Class A for 2.5mm and few patches are found to be worked on.

2)It is performed by using few tools such as sweep,boundary,extrapolate etc..,

Below are the images,

Class C surface

1)Multiple extract tool is used to create the boundary lines separately on side edges of class A surface.

2)Sweep command is used for creating Class C for separate edges from given Class A.Finally merge all sweep surface to get class C surface.

Solid model

Here Class A and C is joined,further it is trimmed with Class B surface.

 

B side features,

Master Section

Master section development takes place during feasibility check and concept validation stages of the product life cycle such as,

1)Master sections are the guides for design requirements that decide the component packaging after technical (Styling, Concept, or Class-A) surfaces.

2)This helps you to decide the feasibility, clearance,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.

Given master section,

Dog house creation

Dog house are basically used to avoid sink marks on the A surfaces, specially at those regions where other attachment features like screw boss is attached, placing such features would add the thickness of the component at that particular region and this would leads to non uniform cooling of the molten platics during moulding resulting to shrinkage of the material from the outer side.

1)The creation of doghouse is done completely using the master section, first we create sketches by taking the refrences from the master section and then we applied the extrude command so that we would get the wall surfaces of the doghouse. make sure we extrude the sketches along the direction of side core tooling axis.

2)It is then made into a closed body and is made into a part model.

3)Shell operation is performed to get a hollow structure and then coring is done in order to avoid sink marks on the class A surface. Drafts are given for the surfaces as per design rules and proper fillets are also provided.

4)The given master section, ribs and supporting features are also added to the doghouse.

Thickness of the part to be 2.5mm

Draft angle for outside is 1.5degrees

Edge fillet for the outer part is 1.5mm and for the inner is 0.5mm.

 

Extruding the cut out

Dog house

Draft analysis

1)Initially part created should be changed into material mode in frame.

2)Compass is enabled and align it along with the tooling direction.

3)Lock command is then classified and Draft angle is applied. 

4)Colour codes are classified and Draft angle is applied.

5)Running point analysis used to display the various draft angle along the part model.

Conclusion,

Thus the A pillar is designed is degined with features such as dog house and performed draft analysis