Week 9 - Project - A pillar Design with Master Section

Aim:

To create the A - Pillar Plastic component through the given Class-A surface and Master Section to create the B side features considering the design rules.

Class A Surface:

The Class A surface is gives is shown in below image:

MASTER SECTION:

The Master Section for Class A surface is gives is shown in below image:

Procedure:

Step 1 : Connectivity of the Class A Surface

• Check the connectivity of the Class A Surface that is to check that there is no gap between the components using the Join command or by visual inspection or also by using the Boundary Command.

Step 2 : Tooling Axis

• The Tooling Axis is created using Bisecting Line Method.

Bisecting Line Method:

In Bisecting Line method is that the possiblities or clearance is checked along the direction using the intersection of surfaces along the axis on the plane of the Class A surface and the two lines is created on the intersections walls that is along the inclined walls of the intersections. Then the line is created by using bisecting line option in line command using the two lines and the point created and that line is Tooling axis.

• For Creating tooling axis we create the point. The image of point is shown below

• In this part we created the two line by using the given master section using Line command.
• Then the the two line bisecting line is created using Line command with Bisecting option. The image shows the tooling axis

Step 3 : Draft Analysis

• Draft anlaysis is done based on the tooling axis. Draft analysis is used to check the Class A is maintained with minimum draft angle of 3 degree.
• The Compass is used define the Draft direction.
• The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the surface. The image shows that draft analysis of the Class A surface with color scale variant.

Step 4 : Creating Class B Surface

• We first Offse the Class A surface with 2.5 mm which is given as thickness by measuring the master section.
• Check for any discontinuity or gap between the joints or boundary is figured out in the offseted surface.
• If any any then by using Multiplr extract, Multi Sections Surface, Sweep are used to fill the gap.
• Thus the Class B surface is created. The image shown below is Class B Surface.

Step 5 : Creating Class C Surface

• The Class C surface is the connection between Class A and Class B surface.
• Then the boundary is extracted using Multiple Extract command or Boundary command.
• Then these extracted surface is Swept using Sweep command with reference surface option is used.
• Thus the Class C surface is created. The image shown below is Class B Surface.

Step 6 : Final trim to obtain A - Pillar Plastic component

• The last step is triming the Class c surface with the Class B surface. Then the obtained surface is joined with Class A surface.
• Then the obtained surface is converted into solid using Close Surface and thus the final Door Trim Plastic Component is obtained. The image is shown below is A - Pillar Plastic component

Step 7 : Dog House Creation

Design rules for Dog House:

C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ) to avoid Sink Mark.

• The height of ( B ) should be between 3.0 – 6.0 mm.

Sketch For Dog House:

• The Sketch is extruded using Extrude command or sweep using Sweep command.
• Then the the extruded or sweeped surface is converted into solid using Thick surface command with thickness as 2 mm.
• Then the intersection is created as per design rule, the wall thickness of intersection witin 40% and the height is between 3-6 mm.The image shows the Intersection of Dog House

• Then the Side Core Axis is created to Draft the inner surface of the Dog House using Draft commnad with angle 0.5 dgree as the seperate Side core is used for manfucturing this Dog house.The image shows the Side core Axis of Dog House

Step 8 : Rib Creation

Sketch For Ribs:

• Based on the Sketch the Rib is Paded using Pad command.
• Then by using Boolean operation the rib is union trimed to the Dog house.
• Then the Draft is done for Ribs by 0.5 along with Side core Axis using Draft command.

Step 9 : Dog House Top Profile

Sketch For Dog House Top Profile:

• The sketch is extrued using Extrude option.
• Then the Extruded surface is Splited with the Dog House.The image shows the Split of Dog House with the Top profile

• Then the created dog house is Union Trimed by Boolean operation to the A - Pillar.
• Then the Fillet is given to the Dog house using Edge Fillet command. The image shows the final Dog house and The A - Pillar with Dog House

Draft Analysis of the Solid:

• Draft analysis is used to check the solid component is maintained with minimum draft angle of 1.48 degree for Dog House as the draft angle is 1.5 degree and inner surface is maintained with minimum angle by 0.48 degree as the draft angle is 0.5 degree.
• The Compass is used to define the Draft direction.
• The green colour shows that the minimum draft angle is provided otherwise cyan color is shown to the solid. The image shows that draft analysis of the solid with color scale variant.

Draft Analysis based on the Tooling Axis:

Draft Analysis based on the Side Core Axis:

Screenshots of the solid model with the proper color code of the draft angle in various orientations:

Isometric:

Front View:

Side View:

Top View:

Picture of the Detailed tree structure:

Conclusion:

Thus the A - Pillar Plastic component through the given Class-A surface and Master Section to create the B side features considering the design rules is created using Catia V5 software.