Challenge

Week 9 - Project - Master Section Development

NNaga Vamsi Kiran Kumar Telaprolu20 Apr 2022

Aim: Create B-surface, C-surface, Screw boss, Dog houses, Flanges, Ribs to the given Class A master section and perform draft analysis to the given class-A surface.

Master section: Master sections are the guides for design requirements that decide the component packaging after technical (Styling, Concept, or Class-A) surfaces. They give reference to some of the features which are indicated in contours.

Steps to be followed:

CLASS A
Tooling axis and draft analysis
B surface and C surface creation
Closed body creation
B side feature creation
Side core axis
Draft analysis

Procedure:

Check the given Class-A surface by using the boundary tool whether any openings in the class-A surface.
Extract the edge lines of the locator which is mentioned in the master section. These lines are further used for the creation of the main tooling axis.
Create the point by taking reference from the locator edges endpoints and selecting between the points and selecting the middle point and creating a point.
From the point and the edge lines of the locators create a bisecting line and take it as the main tooling axis.
Perform draft analysis to the class A surface by taking the main tooling axis as the draft direction.
Create a class B surface by offsetting the class A surface with 2mm, that offset is our class b surface.
Create the plane through the master section by selecting the random three points on the master section.
Intersect the plane with the class A surface to create the section contour of class A.
Extract the edge of the class A surface and smoothen the curve which will be used for generating the flanges on both edges of the class A surface.
Extract the supporting surfaces which help create the sweep surface concerning the extracted curve.
Sweep the curve with the reference surface and adjust the angle to match the master section.
Keep working on the sweep until it lies parallel with the master section by taking measurements between the generated flange and the edges of the master section.
Offset the flange and correct the errors with a multisection surface and join all the individuals.
Similarly, create the flange on another side and trim with the class A surface. Apply the fillet to the sharp edges between the flange and the class A.
Edges creating errors while trimming the off-set flanges with B surface. Rectify them with the multisection surfaces. Trim the flanges with the class B surface
Class A and Class B surfaces are shown in the below picture with an offset distance of 2 mm as measured from the master section.
Now create a class C surface by extracting the boundary of the class A surface and sweeping concerning draft direction using the sweep tool.
Extrapolate the surfaces where they needed to join the surfaces, avoid the errors while trimming, and trim the class C with class A surface.
Trim class B with the trimmed surfaces of class A and Class C. This is our final trim to create a closed body, check the closed body by using the boundary option whether any openings occurred while trimming.
With the help of a close surface we create the final solid plastic part.
Now work on the B side features such as Dog house, Screw boss, etc.,
Create a plane on the master section at the mid-point of the master section.
Using positioned sketch concerning the plane and the point, project the edges of the master section, concerning the projected edges create the outline of the dog house, and constrain it.
Extract the inner side of the dog house and surface extrude it and repeat the same process to the other master section presented on the same plane.
Trim the unwanted surfaces of the extruded edges and thicken the trimmed surface to 2 mm, Then split the thickened surface with the front surface.
We have to reduce the thickness of the dog house at the intersection point to avoid sink marks, Take B = 5 mm C = 0.4 x 2 = 0.8 mm
First, split the dog house with the B surface and use the reference of the dog house sketch and create a profile and extrude. Split the extruded surface with the dog house.
Create the positioned sketch on the top of the dog house and take references from the master section sections. Create the lines for the 4-way locators.
Thicken the created line using a pad tool with a thickness of 1.5 mm up to a height of 18 mm from the top of the dog house. Chamfer the edges of the 4-way locator by taking reference to the master sections.
Add to the dog house and apply fillets and the do draft analysis to the Dog house and the 4-way locator.
Create a Lifter axis as a reference to the dog house, Apply a draft to the inner faces and create a draft analysis.
Union trim the dog house with the B-pillar, Translate the Dog House by taking reference point and plane, and union trim with B-pillar.
Creating Rib using positioned sketch splitting surfaces, draft the faces, Later union trim the rib with the B-pillar.
Take the reference curve from the B surface and create the equidistant points in it, Create the array of surfaces and split with the offset B surface, Union trim them with the B pillar.