Week 9 - Project - Master Section Development

Aim:

To design a B – pillar from given class A surface and master section into a plastic component with engineering features and perform draft analysis on the component.

Objectives:

• To create the tooling axis for the component.
• To create required flanges, class B and Class C surface.
• To create engineering features such as dog house, locators and ribs.

Introduction:

B – Pillar trim:

The B-pillar is the central pillar of the car. This pillar is actually a sheet metal part which is welded in the BIW of the car. The B-pillar trim is attached to the B-pillar and improves the aesthetic look of the car. Mostly the trims are manufactured by the injection molding process.

Master section:

Master sections are the guides for design requirements which shapes the component after technical styling after technical styling of class A surface.

Methodology:

Creation of Tooling Axis:

• Extract the edges of locators in master section.
• Create a point between the vertices of the edges.
• Draw lines using point- point option on the extracted edges.

• Draw a line bisecting the above lines and rename it as tooling axis.

Creation of Flanges:

• Create a plane on the master section with 3 points.
• Create a sweep on the edges of the class A surface using extracted edges by multiple extract command.

• Check the sweep by intersecting the master section with plane created.
• Offset the sweep based on the intersect.
• Trim the class A with sweep.

• Create edge fillets on the edges and rename it as Class A with Flanges.

Creation of Class B Surface:

• Create a geometrical set, name it as Class B surface and extract the surfaces of class A using extract command.
• Offset the surface for 2mm.

• Offset the flanges for 2mm.

• Extrapolate and trim the flanges with class B surface.

• Create fillets on the edges.

Creation of Class C Surface:

• Extract the edges of class A surface with flanges using multiple extract.

• Sweep the extracts with draft direction as tooling axis.

• Extrapolate the sweeps to create class C surface.

• Trim the class C surface with class B surface.

Creation of solid Component:

• In part design workbench, use close surface command on the surface to create solid plastic component.

Creation of B Side Features:

• Dog House
• Creation of B side features include creation of dog house, locators and ribs.
• Create point and plane based on the master section location for dog house.
• Extract the master section for the dog house.

• Create the sketch and extrude for the dog house surface.

• Extrapolate and trim the surface to get the required surface.

• Use thick surface command on the surface to get the solid dog house.

• Locators
• Create the plane and sketch for locator using the plane.

• Pad the sketch to get locator body.

• Chamfer and fillet the locator solid.

• Trim the body with dog house and select the required surface for the surfaces to keep.
• Ribs
• Create sketch for the ribs.

• Extract and extrude separately in tooling axis direction.

• Thick surface the extruded surface for 0.8mm

• Multiple extract the surfaces around the rib extrudes.

• Split the ribs bodies with multiple extract.

• Draft the ribs for 0.5⁰ in tooling axis direction.
• Trim the bodies with B- pillar trim.

Creation of Lifter Axis:

• Create a line using point and plane used in creating dog house and rename it as lifter axis.

Draft Analysis:

• Do draft analysis for final component with tooling axis following the general draft analysis procedure.
• To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.

Tree Structure:

 

Different views of the component:

Isometric view:

 

Front view:

 

Side view:

 

Top view:

 

Conclusion:

   Thus, designing a B – pillar from given class A surface and master section into a plastic component with engineering features and performing draft analysis on the component are done.