Week 9 - Project - Master Section Development

AIM:

To design a B-Pillar from the provided class-A surface

Abstract:

This report describes the designing/approach of designing followed in the industries,In this model we had to create closed solid body from the given class-A surface and later work on engineering features considering every standard design rules followed in OEMs on the B-side of the model.The overview of the approach followed is mentioned below:

• Checking for continuity
• Creating main tool axis
• Draft Analysis
• Creating B surface
• Create Flanges
• Create class C surface
• Create a Closed surface using A,B and C surface using trim tool
• Creating a closed solid part in part design workbench
• Create B side feature(Dog house,Locators,Ribs)
• Creating lifting axis
• Draft analysis of final part

Master section:

These are the guidelines provided to the design engineer which describes how a component should/must be modeled into a solid part by considering its manufacturing process,function and other engineering features from the class-A surface.

Procedures:

Checking for continuity:

From the given class A surface initially it is checked for continuity by using boundary and joint command if any gap found it can be cleared using multisection tool,joint etc

Creating tooling axis:

The tooling axis is created by taking bisecting lines between side walls of the locators and point

Class-B surface:

The class A surface is extracted and the it is offseted to 2mm.The flange at side walls of the B surface is created using sweep tool(with referance to surface)

Creating Flange at A and B surface:

The flange at A surface is created using multisectional extract and sweep (with referance to surface) tht flange angle taken with respective to master section.

Class B with flange

class A surface eith flange

Class-C-Surface:

The edge of the side walls of the class A surface is ectracted and swept using sweep command (with draft axis) the angle is given as 3 deg.The class C surface should be directed outside from A suface to B surface inorder to avoid parting line in A surface

Closed part:

To create the final part the class C surface is trimmed from both class A and Class B and then from the closed body in part design work bench.

Solid closed part:

Using closed surface tool the surface is converted into solid

Creating class B features:

Dog house,locators and ribs are created in B surface considering their design rules

Dog house:

Dog house is an engineering feature that is used in plastic trim design.It is used as a supporting feature for other engineering features like snaps,locators etc that are mounted on the dog house to increase their strength and to avoid the sink marks and also to helps to match its height.Dog house is created based on the mastersection provided.

Draft angle:0.5

Thickness:2mm

4-Way locators:

4- Way locators are use for Locating and arresting components of an assembly. Providing alignment in mating parts

Locators are a great way to make sure that the parts are fitting togather.Draft angle 5 deg,chamfer 5×45

Ribs:

Ribs provide a means to economical stiffness and strength in molded parts without increasing the wall thickness.The multiples ribs are created using copy and paste special

Gap between each rib is 50mm

Draft angle:0.3

Lifter axis:

Side core axis is used to find wheather the B side feature using Point and direction tool the lifter angle is created axis

Draft analysis with main tooling axis:

Green colour indicates positive draft angle -3 deg or more

Blue colour 0-3 deg

Red color negative draft less than 3 deg

Since there is a negative draft in class A surface the styling tem should considered this and do necessary modification

Draft analysis using lifter axis:

Draft angle-0.45

The draft angle clears dog house inner side.

Front view:

Top view:

Side view:

Isometric view:

Conclusion:

Successfully created a solid part from the given class A Surface with engineering features by following their design rules