B-PILLAR MASTER SECTION DEVELOPMENT
B-PILLAR MASTER SECTION DEVELOPMENT
OBJECTIVE: The main aim of this challenge is to develop B-Pillar master section using the class-A surface and intersections for dog house given following rib design rules to create ribs and to perform draft analysis for the plastic component created.
Taking the Thickness of the component by measuring the master sections given and considered as 2mm.
Tooling axis: The direction in which the mold or core and cavity opens is the tooling axis.
CHECKING CONNECTIVITY:
The connectivity of class-A surface is checked by creating boundaries or by visual inspection, by creating boundary we can observe clearly where the surface to be improved and necessary steps to be followed.
TOOLING AXIS CREATION:
Using the master section given the tooling axis will be the bisecting line created using the two master sections and normal to Class-A surface will be created and treated as a tooling axis.
FLANGES CREATION:
Visualising the master sections, we can clearly understand that A-surface will be having flanges and the final component should be created with flanges.
The flanges were created by creating a sweep from the boundary created from the class-A surface using reference curve option.
The flanges will be trimmed with class-A and fillets will be given according to the fillets on master section and this will be the Class-A surface used for creation of Class-B & C surfaces.
CLASS-B CREATION:
As the most surface is flat and don’t have many bends and simple, we can directly offset the class-A surface to the thickness of the component, such that Class-B surface will be formed.
CLASS-C CREATION:
Class-C surface is created using the class-A surface by creating multiple extract of the boundary of Class-A and the surface is swept with the draft.
The class-C will be trimmed with the class-A and the final trim will be trimmed with Class-B to form a complete closed surface.
The closed surface will be converted in to a solid body using Close surface in part workbench.
DRAFT ANALYSIS FOR CLASS-A:
Here we can see the surface is satisfying the draft except at a small particular location which is showing in blue colour.
By visualising the master sections, we can know that there will be a dog house with 4-way locator at the intersection of the master section, so we have to create the dog house and a 4-way locator.
SIDE CORE LIFTER TOOLING AXIS:
A tooling axis should be created for the dog house to clear the draft analysis as an undercut will be formed if we use the main tooling axis so a side core axis will be created.
DOG HOUSE CREATION:
Using the master section, we can create the profile for dog house.
The profile is surface extruded along the side core tooling axis with the required draft produced in the sketch itself and a profile for avoiding shrinkage will also be created. The main use of the dog house is to provide support and to avoid sink marks.
The surface is thickened to the thickness of the component and the body is split for the profile to avoid shrinkage.
Draft is provided for the inner walls, and fillets will be provided to both inner and outer surface.
4-WAY LOCATOR CREATION:
The 4-way locators are also located and created using the master sections.
The profile is padded along the tooling axis direction and chamfer and fillets are provided.
As there are two dog house profiles in the master sections another dog house will be created using the symmetry.
Checking with master sections:
As we can see that the dog house created should match with the master section given, but here in this model an extra profile added to avoid sink marks following the design rules.
DRAFT ANALYSIS FOR DOG HOUSE:
By seeing the below image we can say that dog house has meet the required draft.
RIBS CREATION:
The ribs should be created at a 50 mm distance apart from each other and the design rules should be followed.
The ribs are split according to the design rules.
The final component with all features is:
DRAFT ANALYSIS FOR B-PILLAR:
By seeing the below images, we can say that component has met the required draft except at a particular small portion with blue and red.
The final views of the B-Pillar Master section are:
