Week 9 - Project - A pillar Design with Master Section

MASTER SECTION; MASTER SECTIONS ARE THE GUIDES FOR DESIGN REQUIREMENTS THAT DECIDE THE COMPONENT PACKAGING AFTER TECHNICAL SURFACES. CREATING THIS MASTER SECTION SHOULD NEED 5 TO 6 YEARS OF EXPERIENCE. THIS HELPS YOU TO DECIDE THE FEASIBILITY CLEARANCE PACKAGING AND FIXATION STRATEGY BEFORE WORKING IT ON A 3D. WE HAVE A MASTER SECTION. DRAFT ANALYSIS; FOR MOLDED OR CAST PARTS THE DRAFT ANGLE IS THE AMOUNT OF TAPER PERPENDICULAR TO THE PARTING LINE. IT IS MEASURABLE IN DEGREES. BECAUSE PLASTIC SHRINKS AND STICKS ON MOLDING SURFACES AS IT COOLS WE DRAFT THE WALLS OF THE PLASTIC PART SO THAT IT EJECTS OR BREAKS FREE FROM THE MOLDING SURFACES MORE EASILY AND WITHOUT DRAGGING. TO REDUCE THE RISK OF DAMAGE TO THE PARTS AND ENSURE EJECTION A FUNCTIONAL INJECTION MOLDING PART MUST HAVE DRAFTS ON BOTH THE CAVITY AND CORE SIDES. 3 DEGREES IS A NOMINAL DRAFT ANGLE. 5 DEGREES CAN ALSO BE MANUFACTURED. INCREASING THE MANUFACTURING COST. 7 DEGREES IS CONSIDERED FOR TEXTURED SURFACE PARTS. IMPORTANCE OF DRAFT IN INJECTION MOLDING. REDUCES THE POSSIBILITY OF PART DAMAGE DUE TO FRICTION DURING THE RELEASE. REDUCES MOLD WEAR AND TEAR. ENSURES THE INTEGRITY AND UNIFORMITY OF OTHER SURFACE FINISHES AND TEXTURES. ENSURES A UNIFORM, SMOOTH, UNSCRATCHED FINISH. REDUCES OVERALL COOLING TIME BY REDUCING OR ELIMINATING THE NEED FOR UNUSUAL EJECTION SETUPS. STEPS FOLLOWED FOR DRAFT ANALYSIS. THE CREATED PART MUST BE CHANGED TO THE MATERIAL MODE IN THE DISPLAY FRAME. COMPASS IS ENABLED AND PLACED IN THE COMPASS ALONG THE TOOLING AXIS. COLOUR CODES ARE CLASSIFIED AND DRAFT ANGLE IS APLLIED. RUNNING POINT ANALYSIS IS USED TO DISPLAY PERMISSIBLE DRAFT ANGLE. TOOLING AXIS; IN INJECTION MOLDING THE CLASS A SURFACE IS FIRST ANALYZED TO DETERMINE THE AXIS OR TOOLING DIRECTION THAT SEPARATES THE MOLDS. TOOLING DIRECTION IS CRITICAL FOR PLASTIC PRODUCT DESIGN BECAUSE IT DETERMINES MOLD DIRECTION. TOOLING AXIS; TOOLING AXIS HERE CREATED IS BY SLECTING ONE OF THE NATURAL AXES AS IT CLEARS THE DRAFT. HERE TOOLING AXIS IS CREATED BY EXTRACTING ONE OF THE SURFACE FOR CREATING A POINT AND A NEW AXIS IS CREATED AT THAT POINT. SO A FLAT FACE IS EXTRACTED AND CREATED A POINT AT ITS CENTRE. AXIS IS ALSO CREATED AT THAT POINT. NOW LINE IS CREATED USING LINE TOOL AND GIVING LINE TYPE AS POINT DIRECTION AND SELECTED THE POINT AND DIRECTION FOR CREATING TOOLING AXIS AND TOOLING AXIS IS CREATED ALONG X DIRECTION. CREATION OF CLASS B AND CLASS C SURFACE; CLASS B; TO CREATE THE CLASS B SURFACE OFFSET THE CLASS A SURFACE INSIDE AS PER OUR THICKNESS REQUIREMENT. ONCE THE OFFSET IS CREATED WE CAN OBSERVE SOME PATCHES ON THE OFFSET SURFACE BY TAKING THE BOUNDARY FOR THE OFFSET SURFACE THOSE PATCHES ARE FORMED DUE TO THE FILLETS ON THE CLASS A SURFACE. WE COVERED THE PATCHES BY USING THE DIFFERENT SURFACE COMMANDS IN THE GENERATIVE SHAPE DESIGN WORKBENCH. CLASS C; TO CREATED THE CLASS C SURFACE CONCERNING THE BOUDNARY OF THE CLASS A SURFACE I USED THE SWEEP COMMAND. INITIALLY I EXTRACTED THE BOUNDARY OF THE CLASS A SURFACE WITH TANGENT CONTINUITY AND I SWEEP THE EXTRACTED BOUNDARY CONCERNING THE SURFACE AT 90 DEG FOR 4MM TO INTERSECT PROPERLY WITH THE CLASS B SURFACE. ONCE WE SWEEP ALL THE SURFACE BOUNDARIES OF CLASS A EXTRAPOLATE THE SWEEP SURFACES UNTILL BOTHE SYRFACES GOT INTERSECTED PROPERLY AND TRIM THEM TO REMOVE EXTENDED EXTRAPOLATED SURFACES TO GET A PROPER SWEEP BOUNDARY THROUGHOUT THE ENTIRE SURFACE INCLUDING THE CENTRE HOLE OF THE BUMPER. NOW JOIN BOTH CLASS A AND SWEEP BOUNDARY TO GET THE COMPLETE CLASS C SURFACE. NOW CLASS A SURFACE AND CLASS C SURFACE IS JOINED. NOW CLASS B SURFACE IS ALSO TRIMMED WITH THE OBTAINED SURFACE TO GET THE CLOSED SURFACE. BOUNDARY CHECK IS DONE TO CHECK IS DONE TO CHECK FOR ANY OPEN BOUNDARIES IN THE PART. THE CLOSED SURFACE THEN OBTAINED MOVED TO PART DESIGN AND CLOSE SURFACE TOOL IS USED TO OBTAINE THE PART. DOG HOUSES ARE CREATED BY FOLLOWING THE DESIGN RULES FOR THIS THE SKETCH IS CREATED FROM THE MASTER SECTION PROVIDED. IT IS THEN MADE INTO A CLOSED BODY AND IS MADE INTO A PART MODEL. SHELL OPERATION IS PERFORMED TO GET A HOLLOW STRUCTURE AND THEN CORING IS DONE IN ORDER TO AVOID SINK MARKS ON THE CLASS A AS PER DESIGN RULES AND PROPER FILLETS ARE ALSO PROVIDED. AS PER THE GIVEN MASTER SECTION RIBS AND SUPPORTING FEATURES ARE ALSO ADDED TO THE DOGHOUSE. THEN THE DOGHOUSE IS ADDED TO THE MAIN BODY. ALL THE SKETCHES USED ARE SIO-CONSTRAINT.