Week 9 - Project - A pillar Design with Master Section

A pillar Design with Master Section

A- PILLAR DESIGN WITH MASTER SECTION

CLASS-A SURFACE CREATIONS

To make sure that the given surface has no gap, We can check it visually and also with help of Join or boundary commands.

TOOLING AXIS CREATIONS

Considering the Ejection from the cavity of the mold after manufacturing the interior trim must have a nominal 3-degree draft angle. Hence the tooling axis is created by considering the above factor.

The direction in which the mold or core and cavity open is the tooling axis. In this case below is the tooling axis that I have used. The Line in the CYAN color is our tooling axis.

DRAFT ANALYSIS FOR CLASS - A

Change the view to the MATERIAL mode for draft analysis

select the compass function to align the compass to the tooling direction and lock the direction using the lock function in the draft analysis toolbar

the surface is showing green color so that the surface clears the minimum draft angle of 0.5 to 3 degrees

By using the analyses under the running point we can check the draft angle on the individual faces. It shows how many drafts are on specific points when we move the cursor point.

Green color - above 3 degrees positive draft

blue color- below 0 degree

Red color -between 3 and 0

CLASS-B SURFACE CREATIONS

While offsetting the class-A surfaces to the inward direction, with a 2.5mm thickness of the given plastic parts. The multisection surfaces command solved the class-B surfaces by finding one gap surface, as given below.

CLASS-C SURFACE CREATIONS

The surface of class C is created from class-A surface edges. Class C is often specified for interior surfaces not visible, and surfaces that will be covered by another part when assembled The Class C finish allows more than Class A or B. or surfaces that the Customer feels do not need to meet a high finish. by using the below commands to get a class-C surface, like Boundary, sweep, spline, multisection surface, extrapolate, trim, and join commands.

CLASS-A with CLASS-B SURFACES

By Using The JOIN command to perform the final trimming operations

FINAL TRIM TO GET SOLID SURFACES

To perform the final trimming, select and JOIN the CLASS-A-With CLASS-C Surfaces and CLASS-B surfaces

Go to Part design and make the final trim close body.

SOLID SURFACE BOADY

SIDE CORE TOOLING AXIS CREATIONS

DOG HOUSE CREATIONS

Dog houses are designed to avoid SINK MARK created on the CLASS-A surface by screw bosses and to solve the length issues when giving screw bosses which need to be assembled to other components.

It is also useful when perpendicular screw bosses are required on the part of the tooling direction.

1. C thickness should be 40% of the main wall thickness of T
2. The minimum width of the dog house is 12 mm.
3. The height of B should be 3-6 mm
4. The minimum draft for the do house is 1.5 degrees to die draw.

Procedure for creating the DOG HOUSE

• The first step is to create a side core axis.
• I have chosen normal the point method for creating the side core tooling axis.

Create the dog house by creating a positioned sketch on the z-x plane. Using extrude or sweep method create dog

hose outer walls.

Now close the BACK SIDE wall using the LINE AND EXTRUDE command. Also, Trim to get the required shape of the dog house, All the dong house elements are constructed by using the extract method. for extracting the dog house

Master sections and RIBs and Top cutting elements are all constructed respectively.

Using thicken command in the part workbench, create a solid part of the dog house. and perform the proper draft angles and fillets by considering the design rules.

Sketch for Cutting Element :

Coring operations to split the inside elements

Now, we'll offset this surface by 0.708mm because we need a 1mm width for the walls of the doghouse to avoid sink mark formations and the current width is 1,708mm.

We'll offset it and then extrapolate it so that we can carry out the split operation easily as shown below:

RIBS CREATION

All the dong house elements are constructed by using the extract method. for extracting the dog house

Master sections and RIBs and Top cutting elements are all constructed respectively.

After that, we're going to provide all the required drafts using the 'Draft Angle' command in Part Workbench.

Draft Angle is provided at both the outer and inner sections of the doghouse concerning the Main Tooling axis and Side-Core axis respectively.

DRAFT ANALYSIS FOR SOLID SURFACES

Draft Analysis is a tool in CATIA that identifies the zones which deviate from the specified values of angles along a defined draft direction using color codes.

It highlights the regions of the draft using colors.

Draft analysis is the first step performed after receiving the Class A of the component.

Draft analysis should be passed to make the plastic component manufacturable.

Acceptable draft angles are used as a range for draft analysis that is 0 to 3 degrees.

DRAFT ANALYSIS FOR DOG HOUSE DESIGN

The Dog House draft given is 0.5 to 2 degrees outside and 0.5 degrees inside.

And also the publication of all major operations is identified in an orderly.

isometric different views

details of tree structures below

class-A

tooling-axis

class-B

class-C

please refer to the attached file for your reference in detail.