Week 9 - Project - Master Section Development

REPORT : MASTER SECTION DEVELOPMENT

INTRODUCTION-

In mastersection development,we designed the B-pillar with engineering attachment feature like rib, dog house,4-way locators with the help of given master section.

The master section indicate itself a 2D reference sketch that contains part thickness as well attachments feature information.

DESIGN PROCEDURE-

• Create tooling axis for plastic part as well lifter axis for dog house.
• Make design of plastic part with help of class A-surface,Class -B and class C-surface.
• create attachments features like Rib,dog house ,locator by following design rule.
• Generate the draft analysis to check part fisibility.

CLASS A-SURFACE-

FIG.-CLASS A WITH DRAFT

A) TOOLING AXIS-

• Use the master section and extract the dog house feature lines.
• Create the point bitween two opposit line and create line using ponit and direction feature.
• Again create point of another opposit line and make line through point and give the direction.
• Bisect these two lines and generate the new tooling axis.

fig. reference line 1

fig. reference line 2

fig. TOOLING LINE

fig. Tooling line with master section

LIFTER AXIS-

• The lifter axis is same as to side core axis.
• The side core axis indicate when some feature body is outside boundary with open face.
• Lifter axis indicate when some feature body have open face with inside part geometry.

B)GENERATION OF CLASS B-SURFACE WITH FLANGE-

1.CLASS B -SURFACE : Extract the class A-surface and offset it by 2 mm value which is part thickness.

fig.class A surface offset

fig.Class B-surface

FLANGE GENERATION-

• Extract the outer edges of class A-surface from both side.
• Extrapolate the surface with sufficient value.
• Sweep the both edges with surface reference with draft value.
• The swept surface must match with master section flange edges.
• offset the sweep to coonect the Class B surface and trim it.

fig. class A with extrapolate surface

fig. flange 1

fig.Flange 2

fig. Class B with Flange surface

C) GENERATION OF CLASS C-SURFACE -

• Extract the multiple edges of class A surfacce .
• Sweep the edges with reference to tooling direction with 3 degree outward draft.
• Apply the various commands like multiple section,join, trim,split surface whenever requirement to generate the class C-surface.

fig.class c-surface

D) JOIN THE CLASS A & C-SURFACE:

E) CLOSE SURFACE GENERATION-

• TRIM THE JOIN SURFACE OF A & C WITH EXTRAPOLATED CLASS B-SURFACE

fig. final trim

fig.close surface

F) ATTACHMENT FEATURES-

1.DOG HOUSE-

• Create the mid point by using the master section reference and generate the plane.
• Project the master section sketch of dog house.
• Extrude the surface with suitable length.
• Again extract boundary limit edges from master section 1and extrude it and trim it.

fig.dog house base surface

fig. boundary limit

fig. trim base surface

TO AVOID THE SINK MARK AT BASE OF DOG HOUSE-

• Split the base surface and offset it with 40% of wall thickness.
• Extract the class B-surface and offset it with bondary limit of master section1 .
• Trim the split surface with class B offset surface.
• Extrude the intersection sketch and trim it.
• Offset the trim surface with 1.2 mm value.
• Split it with thicken doghouse body.

2.RIB GENERATION-

• Make a sketch for rib generation and extrude it with suitable value.
• Extract the class b-surface and offset it with 5-times of wall thickness to get rib height.
• Apply the thickness feature to rib surface of 40% of wall thickness value.
• Split the rib surface with offset class B-surface
• Apply the union trim coomand with part body.

fig. rib generation

3. LOCATOR-

• Extract the master section rib edges and project it into sketch workbech.
• Extrude it suitable height with design rule.
• Apply the thickness to locator surface with neutral face.
• Apply the draft value of 0.5 degree.

DRAFT ANALYSIS OF PILLAR B AND DOG HOUSE,RIB BODY-

**Procedure to create Draft Analysis-

1.Open the part file in Catia workbench.

2.Apply the material for part.For that go to view feature>Render style>Customize view parameter.

3.For draft analysis we have to select Insert>Analysis>Feature draft Analysis.Then there will be opening the Draft analysis dialogue box with showing icons like mode, display and direction.

4.Move the compass towards the tooling axis and coinside it with tooling axis.If you want to fix the compass then click on lock icon .

To start the analysis-

1.Select the surface of Part that we want to analysis.

2. click on draft analysis icon .

3.MODE OPTION-

In dialoue box showing mode option with quick & full analysis mode.In that mode feature we can understand the different angle range value in colour format which indicate part is in correct drafft mode or not.The default mode is the quick mode. It simplifies the analysis in that it displays only three color ranges.

* Doble click on colour range which display in dialogue box and we can change the colour range.

*Also by double click on the angle value ,we can modify it.

*The colour mode and respective Draft angle value is set in mode dialogue box.

• When the Draft angle value of the surface is equal or smaller than graduated (fixed in dialogue box) value,the colour will be applied as per graduated value to the surface.
• When the Draft angle value of the surface is greater than greatest value of graduated,the colour of graduated value is applied.

4.DISPLAY OPTION-

1. colour scale-this dialog box only appears in edition mode.Means we have to activate Full mode or Quick mode analysis.
2. Angle Pointer-activate the pointer and move it over the surface which showing various draft value at different locations.

Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circles are displayed indicating the plane tangent to the surface at this point.

3.No highlighted & Representation icon-This feature gives option like on/ off the highligh portion of part.As it enable ,it will show all edges in colour (highlight) format.

4.LIGHT EFFECT-This feature helps to understand the visualisation effect of part under light effect.This light effect will affect the visualiser's eye.

5.Inverse direction- It allows to change the direction of draft angle of selected part.As the we click on reverse direction then there is changing gaduated colour effect ( in negative).It shows the BLUE colour.

5. DIRECTION -

1. LOCKED DIRECTION- In that we can lock or unlock the draft angle direction,a plane,a Face which is used in current analysis.
2. COMPASS- It is used to define the new or current draft direction.To set the compass direction on Tooling Axis,we have to move or pull the compass origin and coinside with tooling axis.

6.Once we have finished the analysing the surface by applying propper elements CLICK on OK icon in DRAFT ANALYSIS DIALOGUE BOX.The analysis is added to tree chart of part.

PICTURES OF DRAFT ANALYSIS-

1.CLASS A-SURFACE-

2.SOLID PART BODY OF CLASS A-SURFACE-

3.SOLID PART B-SIDE SURFACE-

4.ATTACHMENT FEATURE OF RIB WITH 0.5 DRAFT-

5.DOG HOUSE WITH LIFTER AXIS OF 0.5 DRAFT-

6.Surface A & C clear with draft-

1.FRONT VIEW-

2.SIDE VIEW-

3.TOP VIEW-

4.ISO.VIEW-

CONCLUSION-

• Learn to create solid body from class A,B and Class c-surface.
• Learn to surface workbench and it's uses.
• Learn to design the engineering attachments features
• Learn to applying draft analysis features
• Learn to design the part body from given master sections.