Week 9 - Project - Master Section Development

Aim:

To design B-pillar with flanges, Screw bosses, and Ribs with given Class A input.

Class A

Tooling Axis

Tooling axis is created on the basis of the two master sections by ‘Bisecting method’ and draft analysis.

(Draft analysis of Class A with created Tooling Axis and a small patch not clearing draft )

B-Surface Creation with Flange

The A-surface is offsetted by 2mm for the thickness of the B-pillar.

Flange is created with the reference of the master section as shown below

(B- surface flange created is matching with master section)

(B-surface with Flanges and tooling axis)

C-Surface Creation

C-Surface is created with draft angle of 3 degrees to close the A-surface and B-surface to create a complete close body as shown below

(C & A Surface joined)

This Surface is trimmed with the B-surface to create a closed body with thickness of 2mm

.

(Closed Body)

Screw boss Creation

The Dog house and locator pins are designed using Master Sections provided as reference for the location. Below images show the 2-d & 3-d views of Screw boss.

(2-d sketch of 4 way locator pins)

(2-d sketch of 4 way locator pins)

(Screw boss matching the Master section)

(4-way Locator pin matching with the master section location)

(3-d Isometric view of the Screw Boss)

Rib Creation

2-d sketch of Rib is created with distance of 60mm from the screw boss as shown below

(2-d sketch of the rib)

Thickness of the rib is 40% of part thickness of the part 2mm which is 0.8mm

Height of the Rib is 5 times the part thickness which is 10mm

(3-d view of the Rib with draft)

The other Ribs are created using ‘Rectangular Pattern’ options within between distance of 50mm with each other as shown below.

These steps are repeated and the other side of the B-pillar also. The Screw Boss is copied to the other side using the ‘symmetry’ command with mastersection as reference for a midplane.

(Screw bosses and ribs are union trimmed with the main body)

Isometric View of B-pillar with Engineering features

DRAFT ANALYSIS

Closed Surface of B-pillar

The closed surface of the B-pillar clears the draft angle od 3 degrees expect a face show below

A face fails due to the failure of draft clearance in the Class A provided.

Screw Boss

The locator pins and the outside of the Dog house clears the draft Angle of 0.5 degree with the main tooling axis.

A separate lifter axis (blue dotted line)is created to clear the inside faces of the dog house for draft analysis and in manufacturing as shown below.

.

Ribs

Ribs are also drafted with 0.5 degree angle and are cleared in the draft analysis.

Tree Structure

Result :

B-pillar with Engineering features like Screw Boss, Ribs, Flange are designed and Draft Analysed.