Week 9 - Project - Master Section Development

AIM:

To create a B pillar cover with engineering features like dog house, locators and ribs by using the given class A surface with master sections and to perform draft analysis on it.

B PILLAR:

B pillar is the middle pillar and it is a very complicated structure. Because, when the front door is closed, it gets locked with the B pillar and simultaneously the back door is also hinged at this B pillar. So, we should be careful while designing the B pillar. It also provides structural support to the vehicle’s roof.

B PILLAR DESIGN:

TOOLING AXIS:

Initially, we have to check the quality of the class A surface and ensure that there is no gap between the surfaces. Then, we have to create the tooling axis for class A surface by using bisecting method for the lines extracted from the master section.

DRAFT ANALYSIS ON CLASS A SURFACE:

Draft analysis is performed on the given class A surface at an angle of 3 degrees along the tooling axis. The green and blue colors indicate the positive draft while the red color indicates the negative draft along the tooling direction.

CLASS B SURFACE:

Class B surface is created by offsetting the class A surface to distance of 2mm inwards as given in the master section.

FLANGES:

Since, the given class A surface does not have the flanges, we have to create them by extracting the edges of class A surface and sweeping them with reference to the adjacent surfaces. Then, offset the flanges in both directions and trim them with class A and B surfaces to get the output as given in the master sections.

CLASS C SURFACE:

Extract the boundaries of the class A surface and sweep them at an angle of 3 degrees along the tooling direction and trim them with each other to get the class C surface.

FINAL TRIMS:

Finally, trim the class A surface with flanges, class B surface with flanges and class C surface together to get a closed surface as shown in the figure. Then perform draft analysis on the closed surface at an angle of 3 degrees along the tooling direction.

B PILLAR COMPONENT:

After performing draft analysis, close surface feature is used to make a solid B pillar component.

B SIDE FEATURES:

DOG HOUSE (RIGHT):

The dog house is created on one side by creating sketches using the master sections provided and then features like extrude, trim, split and thick surface are used. Draft is provided for the outer faces of the dog house along the main tooling axis. Then lifter axis is created for the inner faces of the dog house and inner faces are drafted along the lifter axis. The thickness of the dog house is reduced to 40% of the thickness of the B pillar at the bottom for a height of 3mm to 6mm. Finally the inner faces are drafted along the lifter axis and edge fillets are given for the dog house.

FOUR WAY LOCATOR (RIGHT):

Similarly, four way locator is also created from the master sections and drafted along the main tooling axis. Finally edge fillets are provided to the locator.

DOG HOUSE AND FOUR WAY LOCATOR (LEFT):

The dog house and four way locator created above are copied and pasted as result with link. Then a reference plane is created in the middle, with point and direction and the copied features are mirrored using symmetry feature.

RIBS:

Ribs are created by drawing lines at equal distances and by using features like extrude, offset, split and thick surface. Then draft is provided along the main tooling direction and edge fillets are provided.

FINAL BODY:

Then all the parts such as B pillar, dog house, four way locators and ribs are assembled to the final body and fillets are provided if required.

DRAFT ANALYSIS:

Draft analysis is performed on the final body along the main tooling axis and lifter axis. The B pillar is drafted to 3 degrees and the features like dog house, locators and ribs are drafted to 0.5 degrees.

ISOMETRIC VIEW:

FRONT VIEW:

SIDE VIEW:

TOP VIEW:

RESULT:

Thus B pillar cover with engineering features like dog house, locators and ribs is created by using the given class A surface and master sections. Then draft analysis is also performed on the final B pillar component.