Week 9 - Project - Master Section Development

AIM :

To create a b pillar of a car using master section and taking class a surface as Input and performing the draft analysis on the final component.

OBJECTIVE :

• Providing the proper tooling axis for the class A surface,close surface and attachment features.
• Taking class A surface as Input and creating class b and class c surface.
• A close surface is created using the class b and class c surface with flange which is obtained from the class A surface.
• To create the proper sketches for the attachment features.
• Adding proper attachment with respect to draft angle.
• To do draft analysis on the final component.
• to create proper tree structure for the b pillar.

PROCEDURE :

• TOOLING AXIS :

Inputs are taken from the given catpart file. which are mastersection 1,mastersection 2 and class a Improved.

from the Input the boundary is taken to check wheather the surface as any connexity error. boundary will display the element as one.

after taking boundary the line are drawn along the mastersection 1 and 2 for creating the tooling axis.

line 1 and line 2 are drawn along the mastersection 2. 

from the other mastersection (mastersection 1)locator edges are extracted. which are shown as green orange line in the mastersection 1. the line definition dialog box is taken and bisecting line option is selected.

from the above extraction and line drawn along the mastersection 1 and 2 are bisected using bisecting lines.

from the two mastersection bisecting lines again it is bisected to form tooling reference axis.then this axis is used as main tooling axis.

• DRAFT ANALYSIS ON THE CLASS A SURFACE :

The Class A improved surface is taken as input then analysis option is selected from the insert option (insert - analysis - feature draft analysis). after opening the dialog box select on the class a improved surface and click on the any of the surface to check the drafting on the material. the draft angle is checked using draft angle dialog box and give the value as 3 deg which is recommend by plastic manufacturing industry. then the compass is dragged and placed on tooling axis which is locked using lock option in draft analysis dialog box.

class A surface is cleared for draft analysis,which is shown in green colour.

you see some of the surfaces are blue colour which determine the draft angle on the elements are above 0 deg but not more than 3 deg . blue colour is displayed when the value are between the 0 to 3 deg.the red colour is the draft angle below 0 deg which are negative values.

• CLASS B SURFACE :

The class a surface is extracted and offseted to 2mm to form class b surface.thickness for the class b surface is obtained from the mastersection inputs.

the class b surface which is offseted With a gap in the the middle of the surface.where the gap is patched using multisection surface.

 

extraction of the edges from the gap and joining them with multi section surface and join using join option.

• FLANGE :

From the master section we observed that b pillar has flange.

for creating the flanges on the class a and class b surface the boundaries are extracted using extract option on both surface and both sides

for supporting the extracted element surface along the element is also selected and extracted.

 

after the extracted surface and element get support sweep is done. class b surface with sweep on both sides.

then the surface is trimed to form class b surface with flange.

same process of flange creation is done on the class a surface to create the close surface.

this is class a surface with flange.

both surface with flange.

• CLASS C SURFACE :

CLASS C surface is created by extracting the boundaries from the class A surface all edges of the class a surface is separately extracted to sweep separately.

sweep direction should be outwards because for clearing the draft analysis of the close surface.

outwards sweep along all edges.

class c surface.

then the sweep surface on all edges are extrapolated around the class a surface to trim with class b surfacealong with class c surface to form close surface.

the extrapolated surface sweep and class b surface are trimmed to create final component which is the final trim.

• CLOSE SURFACE:

close surface is created using trim option which is selected in the final trim option from the close surface option.

engineering or attachment feature :

Dog house ,ribs and locators are the engineering features which are used as attachment features while fitting the component in the automotive part.some locator are mounted on the dog house to increase the strenght of the attachment or joint.

drafting the engineering features will reduce the risk of plastic defects.to create a dog house we are taking the mastersection 1 and 2 as reference.from the mastersection we are drawing the sketch for dog house.

• DOG HOUSE

sketch from the mastersection are taken from the dog house.

then for making the dog house close surface ,the close surface from the sketch is extracted.

after extraction the extrude option is selected are extruded on both sides with 20 mmfrom the master section 1

for completing the close surface of the dog house mastersection 2 is taken as reference and then take the sketch for the closing surface.

extrude the surface to trim with other master section reference section. trimed surface to form the dog house surface.

giving the thickness to the dog house surface.

with dog house formed the inside drafting is done for draft angle clearence or draft analysis.

the inside wall of the dog house is drafted with 0.5 deg with draft angle given throught design rulers of dog house.

THE INNER WALL OF THE DOG HOUSE SPLITED TO FORM THE C SECTION OF DOG HOUSE.

• LOCATORS :

Sketch for locators are drawn above the dog house to use snap feature in the attchment slot.

pad the sketch with the thickness to locate the 4 way locator above the dog house.

thickness for the locator is given with neutral fiber of each side 1.5 mm then the locator are chamfer (pulling direction along tooling axis)

chamfer of 5mm is given to the each  top corner of the locator.

after chamfer the draft for the locator along the tooling axis is given then the loactor is assembled with the dog house to strenght the material support towards the attachment feature.

after attaching the 4way locator with b pillar ,symmetry is taken along matersection line at the middle a plane is created and 4 way locator is symmetried along the plane.

the dog house and symmetried dog house solid are trimmed with close surface.

• RIBS :

By using the locator axis has reference the ribs sketch is drawn with the distance of 110 mm away for the first ribs surface then 50 mm apart for the other ribs which are form along the both sides of the close surface.

sketches for the ribs:

then the ribs sketch are extruded and thickness is given to the extract surface.

class b surface is used for trimming the unwanted solid other than rib section split.

extract the class b surface to trim the rib section from the attachment feature.

after spliting the surface the ribs are created along the close surface and drafting is taken in the rib with using design rulers

after the ribs are drafted the curve extract is taken along the close surface along both sides

then the points on curve is used to create point on the curve.

after creating the point on the curve the repeated points are created to use ribs as reference.

given the instance as 8 with 50 mm aparts ribs points are placed. using use pattern definition the ribs are pattern with repeation points which are mounted on the position.

other side of the ribs are also created using the user pattren definition.

after creating the ribs .the thickness for the ribs are given to trim with the close surface.

 

the same process of union trim is carried out for the other side.

after union trim. fillets are given to the each ribs.

• DRAFT ANALYSIS ON THE FINAL MODEL :

The B PILLAR with attachment surface is taken as input then analysis option is selected from the insert option (insert - analysis -draft analysis). after opening the dialog box select on the close surface with attachment feature and then click on the any of the surface to check the drafting on the material. the draft angle is checked using draft angle dialog box and give the value as 3 deg which is recommend by plastic manufacturing industry. then the compass is dragged and placed on tooling axis which is locked using lock option in draft analysis dialog box.

ribs and dog house are displayed as blue colour because the draft are given to it with 0.5 degree as design ruler when we given 0.5 deg for draft analysis . all parts of the bpillar is drafted.

other side of the b pillar with attchment features.

you see some of the surfaces are blue colour which determine the draft angle on the elements are above 0 deg but not more than 3 deg . blue colour is displayed when the value are between the 0 to 3 deg.the red colour is the draft angle below 0 deg which are negative values.

• LIFTER AXIS :

From the master section plane the point is taken as reference and line is perpendicular to the tooling axis.

this line is marked as lifter axis.

• DRAFT ANALYSIS ON THE FINAL MODEL WITH ATTACHMENT FEATURE USING LIFTER AXIS :

The B PILLAR with attachment surface is taken as input then analysis option is selected from the insert option (insert - analysis -draft analysis). after opening the dialog box select on the close surface with attachment feature and then click on the any of the surface to check the drafting on the material. the draft angle is checked using draft angle dialog box and give the value as 3 deg which is recommend by plastic manufacturing industry. then the compass is dragged and placed on LIFTER AXIS which is locked using lock option in draft analysis dialog box.

This lifter axis is taken as input for draft analysis of the dog house inside . from this picture it proves the lifter axis is consider as tooling axis and clear the draft angle using draft analysis.

you see some of the surfaces are blue colour which determine the draft angle on the elements are above 0 deg but not more than 3 deg . blue colour is displayed when the value are between the 0 to 3 deg.the red colour is the draft angle below 0 deg which are negative values.

for the other side axis is fliped using flip option in the draft analysis.

close surface with attachment feature :(b pillar)

tree structure :

inputs

class b surface

flange 1:

flange 2 :

c surface :

4 way locator :

avoid sink mark :

b side features:

rib creation :

tooling reference :

b pillar close surface :

draft analysis :

publication: