Week 9 - Project - Master Section Development

DRAFT ANALYSIS OF B PILLAR

Objectives:

To create TOOLING AXIS, CLASS A, CLASS B & CLASS C surface for B PILLAR.

To add thickness to B PILLAR.

To design 4 WAY LOCATORS WITH DOG HOUSE & RIBS of B PILLAR & add thickness to it.

To perform draft analysis on final component of B PILLAR part model.

Creation of B PILLAR:

1) Steps to create Class A surface:-

First, create Class A surface using JOIN command to connect different surfaces given in part file. Here merging distance is given 0.1 mm. Rename it as Class A surface.

Publish it using PUBLICATION.

Improvise Class A surface by creating two flanges on both sides of Class A using sweep with draft direction in outward direction with length of 30 mm.

Join these flanges with Class A surface and give 2.5 mm fillet on edges of these flanges.

2) Steps to create Tooling References:-

Select MASTER SECTION 1 & 2 and EXTRACT 4 lines from it.

Create 2 Bisecting lines between these lines. Finalize a Bisecting line between these 2 Bisecting lines & name it as TOOLING AXIS.

Also, create LIFTER AXIS on plane situated at DOG HOUSE as shown in figure.

Publish this TOOLING AXIS as well as LIFTER AXIS using PUBLICATION option.

3) Steps to create Class B surface:-

Here Class B surface must be above Class A surface to create solid part of required thickness of 2.5 mm.

Extract surfaces from CLASS A surface.

Extrapolate these surfaces. Also, offset 2 flanges in upward direction about 2.5 mm.

Extrapolate these flanges and trim them with Extrapolated Class A surface.

Check if any gap remained between surfaces using INTERSECTION CURVE.

Apply edge fillet of 4.5 mm as shown in figure.

Rename this fillet as Class B surface with Flange.

Publish first extracted surface as Class B surface using PUBLICATION from TOOLS menu.

4) Steps to create Class C surface:-

EXTRACT boundary from Class A surface using MULTIPLE EXTRACT with no propagation.

Now, use CURVE SMOOTH option to smooth out every curve extracted from Class A surface.

Apply SWEEP on the CURVE SMOOTH with draft direction option.

Here use CURVE SMOOTH as guiding curve and TOOLING AXIS as draft direction. Apply 3° draft for sweep surfaces. Length of Sweep surfaces should be 20 mm for FINAL TRIM.

Remember that direction of sweep must be outside and not inside.

For corners, EXTRACT boundary separately.

Use MULTI SECTION SURFACE as required between different surfaces with different sections.

EXTRAPOLATE surfaces around corners.

JOIN all surfaces with merging distance of 0.001 mm except corners.

Rename & Publish this TRIM as Class C surface using PUBLICATION.

5) Steps to create B PILLAR PART:-

Connect Class A and Class C surface using JOIN command.

Now, TRIM this with Class B surface.

Check this FINAL TRIM for gaps using BOUNDARY command.

When there is no gaps between surfaces, use CLOSE SURFACE to create a solid body from surface.

In this way, B PILLAR is created.

Creation of 4 WAY LOCATORS with DOG HOUSE & RIBS on B PILLAR:

Create B side features (4 way locators with Dog house) and Ribs on B PILLAR as shown in steps below:

1) 4 WAY LOCATORS WITH DOG HOUSE:-

First, create a center point and a plane parallel to YZ plane on MASTER SECTION.

Create sketch of DOG HOUSE as shown in figure.

Extrude it about 20 mm in both direction and thicken it about 2 mm.

Now, apply 0.5° draft inside & outside faces. Apply fillet of 3 mm on the edges of this extrude.

To avoid sink mark, create surface body as shown in figure. Apply 2.2 mm fillet on outside edges as well as 1 mm fillet on inside edges.

Split this extrude with surface body.

Apply 3 mm on inside edges & 0.3 mm fillet on split edges.

Now, create 4 WAY LOCATOR on top of DOG HOUSE as shown in figure. Add thickness to it about 1.5 mm.

Apply chamfer of 3 mm at 45° angle and fillet it about 3 mm. Apply 0.3 mm fillet on outer edges.

For smoothening purpose, apply 1 mm fillet on remained edges.

Copy & Paste special this 4 WAY LOCATOR with DOG HOUSE with B PILLAR body.

Give SYMMETRY to this PASTE SPECIAL using plane created earlier.

2) RIBS:-

Extract boundaries from Class A surface using MULTIPLE EXTRACT.

Now, create new sketch of two lines as shown in figure.

Create a construction line parallel to MULTIPLE EXTRACT.

Create points at equidistance with distance of 50 mm on this construction line.

EXTRUDE this sketch below Class A surface.

Thicken it about 0.8 mm and give draft of 0.5° angle & fillet required on it.

Apply USER-DEFINED PATTERN for this Rib and perform Union trim with main B PILLAR BODY.

Use same steps to create a set of Ribs on the other side of B PILLAR and at last TRIM it with main B PILLAR BODY.

Steps to do draft analysis on B PILLAR model:

Go to insert > analysis > feature draft analysis or directly click on Feature draft analysis icon from menu.

First select compass option from pop-up menu to set axis system coincide with tooling axis.

Here change position of TOOLING AXIS by moving compass location and use lock option to fix it to give every surface a proper draft.

Surface model will turn into green colour surface, which shows that draft for model is in limit upto 3 degrees. Here I have given green colour for 2 degree draft, light blue for 0 and red colour for negative draft.

Run quick analysis on model and if any draft angle is more than limit, then one can apply new value of it in pop up box.

Full analysis shows different draft angles with different colours as shown in figure.

Here is an example of INVERT DRAFT DIRECTION analysis.

Below image shows the different views of draft analysis of B PILLAR model.

Also, here are images of draft analysis of DOG HOUSE with 0.5 degree draft in direction of LIFTER AXIS.

Here are snaps of feature tree of this B PILLAR model:

Conclusion:

I have learned about creation of 4 WAY LOCATORS WITH DOG HOUSE & RIBS for B PILLAR model in this challenge.

Also, I understand the importance of 4 WAY LOCATORS WITH DOG HOUSE & RIBS design in terms of industry guidelines.