Week 9 - Project - Master Section Development

AIM:

Create a master section development the 4 way locator and dog house for the B-pillar lower section considering the design rules mentioned in the video.

OBJECTIVE:

• Ensure Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set
• A detailed report should be done explaining the draft analysis and the tooling axis creation.
• An explanation should be given on the way of creating the tooling axis particularly the Bisecting method.

PROCEDURE:

Step-1: Connectivity check

• First we have to verify the part design using join surface option by simply selecting the class A surface .
• Another method is create a boundary layer of surface and disassemble it from the boundary layer from the surface.

Step-2: Create tooling axis (Bisecting method)

• Create a reference point by selecting the center circle of surface.
• Then create the axis for the surface to easily define the tooling axis.
• simply select the point and xyz plane.

• To get a dummy tooling axis in x direction.
• Use the intersection command, to get a wire diagram of surface in x direction.
• Use multiple extract to separate the bottom face for tooling axis definition.

• select the intersection command, select first element is plane of dummy axis say zx plane, select second element as class A surface, click ok.
• The draft angle of x direction is created to get the tooling axis of x-direction.
• We will get the tooling axis in x-direction and also define its line color and thickness
• After the dummy axis definition, select the tooling axis of x to bisect using line command.
• The tooling axis for draft analysis is formed.
• Use publication command to publish the class A surface and tooling axis.

Step-3: Perform draft analysis

• Select the draft analysis command, ensure the material feature is used.
• Use quick analysis mode, display color scale option.
• Click on compass command on direction, drag and drop it in tooling axis.
• The draft should show green surface which is feasible draft angle.
• If red is shown not feasible draft angle and for blue negative draft angle.

• Use analyses under running point, to ensure same angle on symmetrical direction.

• Below is fully analyze mode to get the varied angle in class A surface.

Step-4: Create class B surface

• First explorate the surfaces for 10mm length with boundary to be specified.

• Then offset the trimmed surafce from 2.5mm.

• Due to some errors there may be some patches missing. So Create curves and use the multi section surface option.

• Then join the patches with class B surface.

Step-5: Create flanges for both the class A and B surfaces

• Sweep out the flanges for 20mm.

• And trim the side and bottom surfaces together.

• And apply the fillet option measure the edges and enter the value.

Step-6: Create class C surface

• First create boundary of class B surface to from a guide curve.

• Then click the sweep option to select profile type line, draft direction, guide curve as boundary layer and draft direction as tooling axis.

• Follow the same procedure to attain the top layer and 2 holes.
• Then join the side sweep and top sweep togther and 2 holes as well.

• Finally trim the joined surfaces and class C surface to get the final result.

• Also follow the same procedure for the new final part made as C surface.

Step-6: Create dog house

• First create a sketch of a line which is 4 way locator baseline and constraints should apply.

• Pad the line for 5t where t is thickness of the object (2.5mm).
• Also extended the other side for 1 mm or else the object can't be assembled.

• Apply draft angle of 0.5 deg.

• And also apply edge fillet as 0.25 mm.

• And offset it to close the swept dog house baseline and trim it.

• Use the thick surface option.

• And offset it to trim the excess part.

• Extract and explorate the inner part of dog house.

• And offset the base plane to trim the inner wall of intersection to dog house.

• And also apply edge fillet as 0.25 mm.

• Create a body and use boolean assemble option.

• Use Translate or pattern option to move the 4 way locator to upper side of dog house.

Step-8: Create 4 way locator

• Then create a sketch of a line which is 4way locator baseline and constraints should apply.

• Sweep the line for 5t where t is thickness of the object (2.5mm).
• Also extended the other side for 1 mm or else the object can't be assembled.

• And also apply edge chamfer and fillet as 0.25 mm.

• Create a body and use boolean assemble option.

Step-5: Create ribs

• Then create a sketch of a line which ribs baseline and constraints should apply.

• Also extended the other side for 1 mm or else the object can't be assembled.

• Extract and untrim the bottom part of ribs.

• And offset it to close the swept ribs baseline and trim it.

• Also translate the ribs for 10 places by parallel point definition on the extracted boundary.

• Create a body and use boolean assemble option.

• Follow the same procedure to other side too.

RESULT:

• Tree structure

• Isometric View

• Front View

• Side View

• Top View