Week 9 - Project - Master Section Development

By default, we get this class A surface along with two master sections.

In order to create the tooling axis, 4 edges of the master sections are extracted. However two edges of the section are not particularly lines and may cause error while creating the axis, in that case either a separate line using same end point can be created else two other edges at the bottom of the pillar can be taken.

A middle point needs to be taken, from which the axis can be passed and the same point can be taken as a reference for the axis.

A Dummy axis has been created for 1st two edges and needs to create for the other two edges, later which can be used to create the tooling axis.

The two dummy axis can be used to create the tooling axis for the dog house and locator.

Borders to be checked to make sure that there is not discontinuity.

If there is any discontinuity it is need to be removed.

The 4 edges can be extracted in order to capture the feature and fill the surface.

Multi-section surface can be used in order to create the surface and capture it more properly.

Draft analysis for class A can be done in order to check whether it is feasible or not and which areas are going to create problems.

In order to create a plane, it is recommended to create the point using 3 points so that the positioning will be proper.

In order to create the flange for class A and B, the edge is extracted and sweep can be done to capture the flange.

In order to check the sweep angle, it is required to check the deviation and enter the same value, to capture it more better.

After forming the flange and offsetting it for B surface some error is observed which need to be fixed.

In order to create the surface on the curve, a multi-section surface can be used, where we need to give input as a section to be created and guide along which the section can be created.

The same sweep is need to be done for other side and again offset has to be done.

Trim has to be performed to attach the flange to the class A and to remove the unnecessary surface.

After the trim has been done, fillets are required to be added as per the requirement.

once class A is ready, it is required to offset it to a distance equal to the thickness of the component. Also if there are any discontinuity or missing surfaces, those are need to be corrected.

After obtaining the class A&B it is required to capture the class C and for this purpose, it is required to sweep the edges to a certain distance which later can be trimmed with class A&B.

There are several places where the sweep would not work properly and in those cases, it is required to sweep it in parts or use multi-section to create complex surfaces.

After using multi-section, it can be seen that the surface is getting captured and now further trimming can be done.

Once the surfaces are sweeped and extrapolated, trim has to be done to form the entire surface as a single one and later to for a solid.

Once the surfaces are trimmed, solid can be formed from those surfaces.

The dog house is a feature used to avoid sink marks, to solve length issue. These have to be properly captured and a separate draft analysis has to be done for these. First, a sketch needs to be created and the reference can be taken as the master section.

After taking the sketch surface can be formed using extrude command.

2nd dog house also needs to be captured and in the same way, the sketch is prepared and the surface needs to be formed.

After forming both the surfaces trim has to be done and the require surfaces need to keep.

After the trim, thickening has to be performed and this solid then required to split with class B, as class B is the surface that will come in contact with this house.

A 4-way locator also needs to be created in the same way as it is created earlier i.e creating a sketch and padding it with thickness.

After padding the locator, a chamfer is provided for easy entry in the position.

Draft analysis for the locator needs to be done with an angle of 0.5 and all the outer surfaces must be green or blue.

Due to inner nature of the profile, it is better to capture it in the above manner, i.e working on the inner face again, making it more simple and easy to remove.

Draft for inner face has to be done and from the image it can be seen that all the surfaces are green or blue and that is how it should be.

To capture the features more properly these should be connected to the base as well. Here the dog house with the 4-way locators needs to be connected to the base. This is obtained by using the extracted solid and doing union trim with the base.

In order to capture the ribs, a sketch can be created which will provide a base for surface to be extrapolated.

From the image it can be seen that the surfaces are extrapolated and then need to be thickened.

To trim these extrapolated solid, they can be trimmed with surfaces that are 10mm offset from class B. This can be seen above. At certain places the offset would not work properly, then a rough offset can be taken but it is not always recommended.    

After strimming, the draft has to be given, for which the reference surface is taken as class B.

Draft analysis for the ribs has been done. To make it feasible, the rib must appear as either green or blue.