Week 9 - Project - Master Section Development

Aim :

To develop the Cad Model of B Pillar Plastic Component by considering the given inputs Class A Surface by following the design rules followed by OEM Standards.

Abstract

The project deals with the procedure of designing and developing the plastic component and the engineering features act to manufacture in the injection molding process.

Master Sections: During the period of vehicle concept design, the evaluation of master section performance mostly depends on reference vehicle data and the experience of structural design engineers. This paper studies the influence of master section parameters on the vehicle body performance and sets up a parameterized model of the master section. A Master Section is developed based on CATIA/CAA, which improves design efficiency by measuring the master section parameters according to CAD surface data.

• Here in this project, we are going to develop Class B, C, Side flanges and design the Dog House with a 4-Way Locator and Ribs for the B-Pillar.

Note: As the given model is for Practice purposes Class A itself does not have flanges so we need to work on Class A first to get an improved Class A.

CLASS A Surface

Flange Creation :

• Flanges are designed according to the given Master Section.
• Initially extract adjacent surface faces and the boundary of Class-A.
• Then Sweep it Using the Command Sweep with Reference Surface.
• Make sure that the angle of the flange is getting coincide with the master Section.
• make a check for it create a plane parallel to the Master Section and make an intersection with Class A and the Flange.

Class B Surface :

The B surface is created by thickening the A surface. The A surface has no thickness. The B Surface is for Engineering purposes. To thicken the A surface.

Flanges For B Surface :

Class C Surface :

A surface means a visible surface.it will give styler. B surface means the thickness of a part it is not visible it is inside part. c surface means A and B combined to give C surface. Class C surfaces are the backside surfaces that can have tool marks, flashes, and other imperfections without hurting appearance, function.

Class C Surface

Design of B Side Features of the Master Section

• Create a plane parallel to the master section and do a positioned sketch by taking the projection of the master section as a reference.
• Extrude the sketch and design of the dog house component by following the design rules and the master section
• Now give the thickness of 2mm to the Dog House. Then we need to work on the inside coring of the dog Hosue

Design of Dog House C section

• Now we need to take the intersection with the backside surface and make a sketch parallel to the intersection and extrude it.
• Take the offset of 40% less of the main wall thickness and split it from the main dog house.
• Now Provide the minimum draft for the inside walls of the C-section.

Draft Analysis of Dog House

Design of 4 Way Locators

• Draw the sketch for the locators on the dog house and pad them in the direction of the tooling axis
• Apply the entry chamfer and edge fillets according to the design rules.

• Now apply the minimum draft angle to the walls of the locators.
• Perform the union trim with the Dog house.

• Now Union-trim the Dog House with the B-pillar.

Design of the Ribs

• Draw the sketch for the Ribs and make sure that the ribs should not overlap near the dog house.

• Extrude the sketch of the rib and provide a minimum thickness and split the rib by the offset walls of the Class-B surface.

• Split the other side about which the material is not needed.
• Provide the minimum draft and fillet for the ribs
• Now Extract the boundary of Class-B and create points along the boundary using Point Repetition Comm
• Now using the pattern Command create the number of ribs required.
• Now to create the same ribs on an uneven surface use the pattern before the split.

B Pilaar Draft Analysis

B Pillar With B Side Features

Tree Structure :

Result

Finally, the flanges and the B side features are created along with the B Pillar with the help of the Master Section.