Week 9 - Project - Master Section Development

Steps In Development of Master section of B Pillar :

(Note : Class A surface needs to be improved for this Master section. There are many defects In this Class A Surface)

1) Offset the Class A surface at required thickness in the inner direction. Due to offsetting there will be formation of open areas in the offset surface which needs to be cleared to form close body.

2) Creation of Tooling Axis :

For construction of tooling axis extract the parallel vertical lines from the "master section" and bisect them to get our Tooling Axis.

3) Creation of Flanges :

Extract the edges of the Class A body and then sweep it in outward direction. Make the use of interstion between Master section 2 and the body to get the proper angle of sweep for the flanges.Before joining those flanges with the A surfce offset them in upper direction so that we can provide flanges to B surface too. Now join Flanges with Class A surface to make a single body.

4) The surface we offsetted in the inner direction is the required B surface. Extrapolate the edge of the B surface at the required extent. For the flanges use the offsetted flanges and trim the off with B surface.

Now give required fillet to the sharp edges.

5) Creation of C surface :

For C surface sweep the edge of the Class A surface in the tooling axis direction at 3 degree.

Now trim this surface with the B surface to get the required surface. Make this body solid in the Part Body using "Closed surface" command. 

6) Do the draft analysis and ensure that the body is fully cleared in draft analysis by keeping the draft of around 3 degree.

7) Creation of DogHouse with locator:

For construction of DogHouse extract the lines form the Master section and extrude them into Generative Shape Design and trim off with each other. And then make it solid in the Part Body by giving it thickness according to the master section. Now for locators create the sketch on the head of the DogHouse and then pad it by selecting the thick option. Give the chamfer to the locator and then make it union trim with doghouse. Provide proper draft and fillets to the doghouse and the locator.

To make the undercut in the doghouse, extract the backside inclined surface and then extrude and trim it with the doghouse surface body. Give the offset of 40% of the thickness to the undercut.

Now split it with the doghouse in the outward direction to get the lower undercut in the doghouse.

8) Creation of ribs :

For ribs, first create the mid line through ther B pillar. Now make the solid rectangular surface in the B pillar and then increase the instances as per the required support to the B Pillar and give the spacing of 50mm between each ribs. Now offset the B surface at some extent in the inner side according to required length of rib and then split it with ribs to get the required ribs profile. Provide the draft of 0.5 degree to the ribs 

9) Make the Ribs, Doghouse and the B pillar Surface a single body & do the draft analysis on the body.

Draft Analysis 

(Note : Since there is defect in class A Surface and the master sections provided so we created our own master sections)

Creation of Master Section 1:

Create a plane using three point method.

For Master Section 2, take the axis in the middle of the doghouse and intersect it with the part body.

Defects in Class A

Different Orientations

Isometric View

Front View

Top View

Side View