Week 9 - Project - Master Section Development

B-PILLAR DESIGN USING CLASS A SURFACE AND MASTER SECTIONS

AIM:

    To create a B-Pillar design out of Class A surface and follow the master section for creating B side features.

OBJECTIVE:

• Ensure using surface command.
• Use of close surface command to create the solids
• Rename geometrical set properly.
• Follow the Master section to create flange
• Follow the master section for thickness and to create the Closed volume.
• Follow master section to create Attachment features
• Ensure proper tree structure.

PROCEDURE:

    To design a plastic component, The first step is creating a tooling axis.

TOOLING AXIS:

    Tooling axis is the direction where the core travels to the cavity in the manufacturing process. Hence it must be created at first so the the component which ig going to be designed can be created along the tooling axis for easy production.

    Lets say we got our Class A surface...

    Now we have to create a tooling axis for starting design process. To create the tooling axis, the direction consideration should be in a way that when the core travels, the component must not interfere with any other features which blocks in the view of the direction.

    In this case, I have taken Y direction as my tooling axis since the class A surface is most likely to be in the favor of Y direction for producing the part.

    The cyan dotted line is the tooling axis we created.

    Since the tooling axis is created, now we can start designing the component efficiently.

CREATION OF B SURFACE:

    Class B surface is the surface which is offseted from the class A with a value of the thickness the component should be.

     Here in this case, the thickness specified here is 2mm. Hence the B surface was  offsetted 2mm from class A.

CREATION OF CLASS C SURFACE

    Class C surface is the joining surface which joins the A and B surface with specified thickness. It helps to form a closed surface and with the help of that, a closed body will be created.

    The Yellow surface which boundaries the A and B is known as Class C surface.

CREATION OF CLOSED BODY:

    From all the A, B, and C Surfaces, using a command called Close Surface, can close the surfae and become solid.

CREATION OF B SIDE FEATURES:

Master Section:

    Master Section is a 2D drawing which consists of necessary dimensions to create a 3D feature on a part. The master section can be used to create B side features or just the whole component depending upon the 2D drawings.

GIVEN MASTER SECTIONS

CREATION OF DOG HOUSE AND 4 WAY LOCATOR:

    using master section as reference, the dog house and 4 way locator is created as shown below.

    Since the dog house has a hole inside it and cant be cleared using just a main tooling axis, here we create one more axis which is known as Lifter Axis.

LIFTER AXIS CREATION:

    Lifter axis is the direction in which the lifter travels to clear some tooling features of the part where normally main toooling axis cant be cleared. Hence a seperate tooling axis is created to accompany the creation of additional features which fails the tooling axis.

    The brown dotted line represents the Lifter axis.

CREATION OF RIBS:

    Ribs provide strength to the component against bending or damage. hence to components where the surface is flat may result in bending due to stress or tension. Hence ribs are created.

    These ribs are placed 50mm between each other to facilitate easy production and cost and material savings.

DRAFT ANALYSIS:

    Draft Analysis is a process of checking whether the component which produced along the tooling direction can be manufactured or not. Before starting, a minimum draft of 0.5 DEG.

Draft Analysis of Class A surface:

    As we can see, almost 95% of the A surface cleared the Tooling axis. the patches which are in blue and red are the areas where the tooling axis cant cover.

    Hence there will be a requirement to contact the surface styling team for modification if the class A surface since the NPD team cannot modify for their own comfort.

    Otherwise we can tilt the tooling axis in such a way so that it cleares the patches, burt the problem arises where we start designing the b side features since it is considered for Y as tooling axis here.

    So by change in tooling axis, we may lead to see an inclined dog house which wont be similar to the master section provided.

    Hence the best solution is to return the class A to the styling team for modification and then start designing the part.

Draft Analysis of Plastic Part:

    The part which we created finally needs to be checked using draft analysis since the feature after design should e cleared using the main tooling axis.

    As we can see here the B side features are also cleared using the main tooling axis except the dog house which is obviously going to clear using lifter axis.

    As we know nthe lifter axis also cleared the dog house. Now the component is all ready to be manufactured.

3D CAD MODEL:

TREE STRUCTURE: