Week 9 - Project - Master Section Development

                                                                                          MASTER SECTION DEVELEPOMENT WITH B PILLAR

What is Master Section?

Master Sections are the guides for design requirements which shapes the component after technical styling of Class A Surfaces.

The design features are created on the guidelines of the master sections after the Class A creation.

    

                  CLASS A SURFACE                                                                            MASTER SECTION

  

               FIG 1                                                                  FIG 2

With the help of above master section , we have to predict the exact design feature to progress with the model. As of we came to know that in fig1 it could be a dog house with 4 way locator placed on the above of the dog house. The extension of the green line denotes that it can be a flange of the outer section of Class and Class B can be closed using sweep feature.

In fig2 the two yellow lines denotes a design of a rib tangent to the surface with the distance of nearly 50mm between the ribs.

CREATION OF TOOLING AXIS

To proceed withnthe further design models , the creation of tooling axis is very imporatant. So, here take the reference lines of the dog house master section for tooling axis line.

 

Using the Extract feature, extract the lines and create a reference point using the between point type for an center point. Create a line with point as reference. Same as to be done to the another two line and create a line and bisect both to create a common line for the tooling axis .

    

CLASS A SURFACE AND ENGINNERING FEATURES

  

In the above imgaes lower lines are as class A and upper lines are Class B surface.

Extract the outer boundary lines to create a sweep and multiple extract the faces which connects the boundary lines. Adjust the sweep angle  according to match with the master sections with intersection lines as reference. 

    

Same as to created to the both sided surface and trim them to complete the Class A with the enginnering features.

   

CLASS B SURFACE 

As we already known we have to offset the Class A to form Class B surface . THickness value can be refered through the master sections.

  

After the offset of 2mm, using multiple extract the boundary lines has to be sweeped on both sides of the surface and extrapolate  the required areas to trim the surface for Class B.

    

Check with the master section lines whether it matches with Class A and Class B.

 CLASS C SURFACE 

To create a Class C sweep the outer boundary sections to intersect with the Class B. Mutiple extract the outer boundary to do sweep.

     

The lefted portion of the class A can be closed by multisection bodies feature. 

  

Join the three surface as one multisection and two sweep surface to a single surface and extrapolate them to trim with other sweep feature.

    

Same as to be done on the other side of the surface.

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Extrapolate the required areas to do a trim feature and close the class C .

 

In this we cant create a sweep here due to uneven surface.  Create a line and split them to create a sweep.

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CLASS C FINAL TRIM

  

Closed Surface

CREATION OF ENGINEERING FEATURES

In this master section we can see some of the engineering features to design. They are

• DOG HOUSE 
• 4 WAY  LOCATOR PIN
• RIBS

DESIGN OF DOG HOUSE 

    

The dog house creation, extract the line to create a point as an explicit and place the yz  plane with point as a refrerence. Project the master section using the plane and make them as fully constrained sketch for extrude the lines.

       

To know the length of the dog house create an extrude to front and back of the surface and trim the unwanted portion of the dog house. And thicken the surface of 2mm outward direction.

    

The inner portion of the dog house has to do an undercut. And split the thicken surface with the class A to delete the extra portion extended beyond the class A.

 

  

 

4 WAY LOCATOR PIN

    

Project the master section and constrained the sketch. Padup the sketch of 20mm and aplly the required fillet ad chamfer. And union trim with the dog house to be a single solid part.

The same dog house has to be designed on the other side of the part. So we can copy the dog house and using paste special with result link we can symmentry the body to the other side.  The referene point is to be created betweeen the to end points of master section dog house.

CREATION OF RIBS

 The ribs are created to give a stiffness to the part. Here in the master section we know that the distance between the two ribs is of 50mm and the other dimensions are followed to the design rules of the rib.

  

Sketch of Rib

    

Create a point and plane to a offset of 25mm , draw an line with lngth 0f 60mm clearence, hence it was claculated form the middle of the dog house. Extrude the sketch and thicken the surface , and create an multiple extract and offset of 10mm towards front and perform the split operation to get a design of rib. Afer completion of split operation , union trim the thickned rib to the closed body surface select the outward portion as an removed face. 

  

Same kind of mehod has to be followed to the other ribs. We can perform a lnear pattern or user pattern feature to copy the ribs. In some of the areas of the surface it looks uneven. So i have designed sepaarte sketch each and every sketch with reference has same plane and sketch.

     

Union trim the created ribs with the created closed body part , select the outward faces as an faces to remove. Before split apply the required draft , after compleion of split give required filllet radius to the ribs.

  

Creation of Lifter Axis

The specific requirement of lifter axis is to clear the inner faces of the dog house. The side core cant be used here because its placed inside the surface part model. The lifter axis can be used here it was placed inside the mould. 

 

TREE STRUCTURE

          

 

          

 

  

Differential Views of Part Model