Week 9 - Project - Master Section Development

Aim: To design B-Pillar lower using the Master section.
Objectives: Create a closed body of the Given B pillar Lower.
Create tooling axis and follow design rules.
Follow the Master section to create a flange.
Follow the master section for thickness and to create the Closed volume.
Follow the master section to create Attachment features.
DESCRIPTION:
MASTER SECTION:
Master Sections are the guides for design requirements that shape the component after the technical styling of Class ASurfaces The body frame is mainly composed of floor longitudinal beams, upper side beams, door side beams, andfront cover, the rear beam, A-pillar, B-pillar, C-pillar, and other load-bearing beam structures are composed. MasterSections are parameterized model of the vehicle body that outlines the guidelines for the NPD Team. In this Report, BPillar Cover Creation with detailed procedures of Surface Development and Attachment features are covered.
OVERVIEW OF DESIGN LIFE CYCLE AUTOMOTIVE INDUSTRY:
The Stages of the Design Life Cycle are:
Concept Sketches: Concept sketches are rough ideas of freehand sketches obtained through the styling team and willbe used to prepare the Model. It is usually done through pen and paper and through the painting software. This will beused to generate the concept for preparing the model by incorporating various styles and information obtained fromthe stakeholders.
CLASS A Creation: -After finalizing the concept the sketches are usually worked in software such as Autodesk Alias tocreate Class A Surface.
Clay Modelling: -The Class A Surface is concurrently worked by clay modellers to brainstorm and benchmark the stylingof the product and later the Concept is validated by bringing up a rough clay model and then it is passed on to theDesign team for the preparation of New Product Design (NPD) CAD.

PROCEDURE:
The procedure followed in the creation of the plastic New Product Design are
Tooling Axis
B Surface Creation

C Surface Creation
Closed Body Creation
B Side feature Creation
Side core Axis creation
Draft Analysis
The given Class A input is analysed to envision the part to manufacture and the Tooling axis or Tooling Direction or Dieline is the direction that moulds pull apart in injection moulding. There are two mould pieces names core and cavity.Thus, tooling direction determines Mould separation and also becomes vital in developing the plastic product which isdrafted to desired nominal angle for feasible clearance and ejection of the final part from the mould.
Step 1: Create a tooling axis.
For creating the tooling axis first we extract these 4 boundaries.

finally, we got the tooling axis

Step 3:
Creation of Class B & C Surface.
According to the Master section, our component has a 2 mm thickness so we offset the class A surface by 2mm.
After offsetting the surface, we can observe that the CLASS B surface is having a patch / missing surface. This surfaceneeds to be fixed by manually creating a surface. To create a surface over the patch, we first need to extract theboundaries of that edges separately and using the “multi-section” option a new surface can be created. Now join thispatch surface with the offset surface to form a CLASS B surface. So, to clear this use multi section surface option to closethe gaps formed. The gaps formed are closed and the Class B Surface Formed is Ok.

CREATION OF FLANGE:
From the master section, it can be observed that the B Pillar is having Flange but the CLASS A surface which was given tous as input does not have any Flange. So, to create a Flange on both A & B surfaces we first need to extract theboundaries of the CLASS A / B surface as shown in the figure below. After extracting the boundaries apply a smoothoption to it to avoid any surface continuity issue

Surfaces of CLASS A / B which are attached to the boundary need to be extracted first which will act as a referencesurface for the Flange while sweeping. Now sweep the boundary with the reference surface (surfaces which weextracted) and give an appropriate angle such that the Flange is aligned with the master section. Offset the SweptSurface to 2mm. Similarly, Do it on the other side of the B Pillar

Now Join the Sweep surface with the Class A surface and the Offset surface with the Class B Surface to get surfacesattached with a Flange. and now provide the fillets by measuring in class A
CLASS C SURFACE CREATION:
To create a CLASS C surface, first, extract the boundaries (all edges separately) of the CLASS A surface (the surface withFLANGE) as shown in the below figure. After extracting the boundary, we need to perform a smooth (max. Deviation as0.001mm) operation on it to create a continuous tangent surface.
trim the sweep after extrapolating them.

FINAL TRIM:
To create the B Pillar component, we need to join all these surfaces (i.e., CLASS A, B and C surfaces). First, join the CLASS Asurface with the CLASS C surface and then trim this joined surface with the CLASS B surface to get the final output.

ENGINEERING FEATURES:
DOGHOUSE:
Doghouse is an engineering feature that is used in the plastic trim design. It is used as a supporting feature for otherengineering features like snaps, locators etc. that are mounted on the Doghouse to increase their strength and to avoidthe sink marks.
To create a Doghouse, we need to follow the master sections which were given to us as input. The top surface and thesupporting walls of the Doghouse on which the locator is laid are created by simply extracting the lines from the mastersection in a sketch and extruding them to a certain length as shown in the figure below.

Since we need to create multiple ribs which are 50 mm apart, first go to the CLASS A / B surface and extract theboundary/edge where the flange is connecting to the main body. Now using these boundaries, create repetition pointsthat are 50mm from each other.
Now copy the rib (solid body) that we created and paste it into the main tree structure. Using the translate option thecopied rib can be moved from one point to another. Repeat the above step for creating all the ribs and position them onthe points that we have created using the repetition points option. Offset the CLASS B surface to 10 mm and trim the ribswith it removing the excess portion of the ribs and giving a draft of 0.3 to the ribs.
Create the ribs on the other side also. Once all the engineering features are created, add it /trim it to/with the main bodyi.e., B Pillar and give appropriate fillet value to all parts of the body

CONCLUSION:
A component with the engineering features such as ribs dog house, flanges has been created by using the designconsiderations and rules for the given class A surface and draft analysis is performed.