Challenge

Week 9 - Project - A pillar Design with Master Section

A PILLAR MASTERSECTION:

Darft analysis:

Draft is a provide an angle to plastic component with cavity to reduce the friction .
without having the draft it may causes the shape was resized .Output of a component is become unsatisfied.
The minimum draft to any plastic component should be 0.45degree hence the class A surface of A-Pillar master section is analysed for a draft..
Hence in order to have minimum sidecore involvement and minimum cost we must have the tooling axis in line to the axis of the base at the surface centre.
Draft analysis can be done through tooling axis . select a compass on the draft analysis set on the tooling axis and lock it.
Select the material option customized view parameters click ok.
click on the surface it will be visible as green in colour. Class A and Class C surface are in positive angle and Class B to be negative angle.
in the class-A surface have a conflict on that it was not clearing draft analysis of 3degree
It was clearing an angle of 1.90degree
For the Dog house is 0.49 degree for the outward dog house and second one is at lower it is done with 0.49 degree it was cleared.

Tooling axis:

Commonly we are consider holes in the class A surface than class A engineer was consider to construct a tooling axis from centre of the circle
But here dont have a circle and have only flat suface so we are using flat surface it was clearing analysis.
We have visulaized the diagram in certain directions in y direction image was totally appeared.Extract the flat surface make a point that as middle given as 0.
use point direction draw a line in y direction form a tooling axis. it obeys the closed surface but not engineering features so we create through another master section.
we have do another method bisecting method to check form axis system take master section as reference line extract vertical lines and use bisecting method line was formed between them .
use two points between command to form a point between them take as main point.
Use this tooling axis do the drafting analysis on the Class-A surface for intial and final conversion of solid surface draft analysis.
Tooling axis can be form through Bisected method , Normal surface method,point direction method .
Differ result in tooling direction and bisecting method so we are go with bisecting method through master section .

Side core tooling axis:

Extract the surface of the Dog house front phase and create a point as 0 inthe middle .
take a point direction method draw a perpendicular line to extract surface that is in z direction .from z is taken from axis system
finally it is a side core tooling axis.

Construction:

For every surface geometric set are to be added to choose easy to understand .

Body was in the part body.

Class -B surface:

first we are offset the given class into down direction.
Change the graphic colour to offset .patches was appear.
Extract the side edge and line with tangent continuity .use sweep command of with reference surface give profile as side edge and guide as line .
Class-B surface was formed.

Class -C surface:

select the outer boundary of the A-pillar of Class-A use reference surface sweep with 90degree for side surfaces with inward direction and divide into several portions than join them
For the front and back area did a sweep of draft direction with 3degree and extrapolate the front and back sweep for extra lines to trim them .Both are in out ward direction.
join C + class-A
If their is any gaps check with intersection command their any black points are visible are not.If visible to extrapolate that surface to fill.
Join A +C

Final trim:

Select joint of Class-C and Class -A trim with class -B to remove unwanted material finally of wanted object material was formed .
For checking their any gaps in the surface to check use boundary to click on the surface its shows error means thier is no any gap.

After that Define part body with the command of closed surface in the part work bench to make a surface body into solid body.

Dog house:

Create a point on the side of vertical line of master section of inner line and form a axis system on that point givce a X-axis and Y- axis lines are assign .
Z-axis to be kept as free .
create a sketch take XY as refernce plane give a point.Extract the lines and constrained them and use extract command to extract in 27mm 20.452mm in forward direction and 6.548 mm in back ward direction .
Total of 27mm take this length from the master section .
create multisection surface through extract the back and top lines side lines as to support and guide as top extracted line .Join the extrude and multisection surface.
Use thick surface command to chage surface into solid with 2.5mm thickness.
Use Draft to mlultisection surface of 0.5degree to give an angle to move to remove from the mould .
Remaining faces are Already drafted in the master section.
Create a body convert the surface into solid through thickness command of 2.5mm
Give a edge fillet of 1.5mm for outward edges and for inward 0.5mm.
Extrat the inner faces and take xy plane and create a line on that with a distance of 12mm from horizontal axis and constrained them.
create multisection surface on back side of the extract surface to fill that back space and join them
offset to outward direction in 1mm and use spplit command to split the surface from main dog house.
inner doghouse edges at 0.5mm as fiilet was given .
Do a draftanlaysis with 0.48degree outward faces are passed in the draft analysis.

RIBS:

Extract the lines from the master section and create a sketch with the extract lines and constrained them.
First we create the base extract from master section thean thicken with thickenss command with 1.5mm .
Define the rib base and extract the rib lines from master section and extrude them and define work object to rib base and thicken the extrude of 1mm and create a paste special with result link .
Use translate command to dupicate solid into certain distance take a distance from master section to apply it.
Define to rib base ribs was union trim with rib base .
Use Boolean operation define Dog house union trim with ribs final solid was formed .
Do a Draft on the sides of ribs and top base of rib base ttahn take a neutral axis as bottom rib base .
Give a fillet of 0.25mm on the sides of rib and which rib areas are connected to dog house in that spot gave a fillet.
Design rules:
Rib draft=0.5degree
top thickness=0.75mm
Rib fillet =0.25mm
Rib length=<5*t. wall thickness=t
Rib thickness=0.4*t =0.4*2.5=1

TOP CUT HOLE:

Extract the top phase create a point on the midddle than form axis system on that point .
assign the x and y to lines inthe master section .
Take Zx as plane and sketch the circle on top create a lines and symmetry to horizontal axis with 22.5degree and distance between the lines another end which was connected to circle is 3mm.
Remove the circle between the lines.iso-constrained the lines and circles .
use pad command to pad it in both directions above as 5mm and below as 4mm .
give a fillets as edges of 0.25mm and apply draft to sides and neutral phase is bottom phase and pulling direction is main tooling axis with draft angle of 0.5degree.
Use boolean operation remove from the dog house .

Fianl body:

Add the dog house to part body with solid surface.do a draft analaysis with main tooling axis and side core axis as 0.48degree.

Publications:

Class-A,Class-B,Class-C and Tooling Axis ,side core tooling axis ,solid surface publications are in the Publication part body.

Note:

iT was a report to Class-A engineer it was not clearing draft at 3degree i was add a images of 3 degrees in this report.
In the class -A surface was did only at 1.9 degree through toolin axis bisected from the master section lines.
i was mentioned and add the images of degree images and 1.9 degree images

Note:I am using the CATIA VERSION OF 2011 please consider it.

CLASS-A SURFACE: