DEVELOP B-PILLAR FROM GIVEN CLASS-A SURFACE AND MASTER SECTIONS. ALSO ADD ENGINEERING FEATURES.

AIM : DEVELOP B-PILLAR FROM GIVEN CLASS-A SURFACE AND MASTER SECTIONS. ALSO ADD ENGINEERING FEATURES.

OBJECTIVE : 

1. Draft analysis of given Class-A surface.
2. Create Class-B and Class-C surface with reference to Class-A surface.
3. Add material to close body. And Create Engineering features.
4. Draft analysis of the B-Pillar master section.

B-PILLAR

• The body of an automobile is made of a structure, which include the roof, the pillars, and the floor. The car pillar in the vehicle stands in the near-vertical position, which supports the vehicle’s roof.
• There are four type of pillars in car, which are as follows

1. A-Pillar
2. B-Pillar
3. C-Pillar
4. D-Pillar

• The manufacturers identify the car pillars from the side while moving from front to rear of the vehicle.
• B Pillar is the most complex component/structure of the vehicle body.
• This is because the front door closes on the B pillar while the rear door hinges onto it.
• The B pillar or the center pillar in vehicles is made of steel.
• It is welded to roof panel on top and the vehicle’s floor pan at the bottom.
• This pillar provides structural support to the vehicle’s roof.

MASTER SECTION

Master sections are the guides for design requirements which decide the component packaging after technical (Styling, Concept or Class-A) surfaces.

SCREW BOSS : 

• A boss feature finds use in many part designs as a point of attachment and assembly.
• The most common variety consists of cylindrical projections with holes designed to receive screws, threaded inserts, or other types of fastening hardware.
• Under service conditions, bosses are often subjected to loadings not encountered in other sections of a component.
• Provide a generous radius at the base of the boss for strength and ample draft for easy part removal from the mold.

DOG HOUSE : 

• Dog house is an engineering feature used in plastic trim design.
• Dog houses are used as supporting feature. Sometimes other engineering features like snaps, locators etc. are mounded on them to increase their strength.
• Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity.
• Dog house and other engineering components are built on B-surface. 

GENERAL GUIDELINES FOR BOSSES : 

• Draft  - 0.5 degrees on walls of boss
• Thickness -  Typically 40%* of the nominal wall at the base.
• Height to Diameter Ratio -  3:1
• Radii - 0.25mm maximum radii.  

GENERAL GUIDELINE FOR DOG HOUSE :

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ). 

• Height of  ( B ) should be between 3.0 – 6.0 mm

PROCEDURE : 

CLASS-A SURFACE

Class A surface refers to those surfaces which are VISIBLE and abide to the physical meaning, in a product. This classification is primarily used in the automotive and increasingly in consumer goods

GIVEN CLASS-A

CLASS-A WITH FLANGE

As per given master sections there are flanges in the B_Pillar, So I modify the Class-A surface with flange.

STEP 1 : TOOLING AXIS CREATION

• To perform a Draft analysis the tooling cration is very mandatory. To create a tooling axis analize the best direction for it. In this perticular component the Y-direction is very convenient to create the tooling axis.

STEP 2 : DRAFT ANALYSIS ON CLASS-A SURFACE

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction. And move curser to part and select point and it shows the green color which represent the draft angle is 0.5 or above.

STEP 3 : CLASS-B SURFACE CREATION

• From given Class-A surface create a Class-B surface of an offset of 2 mm as a given thickness.
• To create a Class-B surface we have to extract all the boundary of improved Class-A with flange.
• Then provide an offset of 2 mm.

STEP 4 : CLASS-C SURFACE CREATION

• To join Class-A and Class-B surfaces we have to create a Class-C surface.
• To create a Class-C surface we have to extract the boundries of the Class-A surface.
• After that use the sweep command to sweep the boundries along with tooling axis as an second guide curve.
• There will some minor gap between Class-a and Class-C surface due to draft angle.
• To overcome this problem extrapolate the class-A and Class-C surface and trim it.
• After that join the Class-A and Class-C surface using the join command.

STEP 5 : CLOSE SURFACE CREATION

• To create complete close surface trim the Join of Class-A nad Class-C from the Class-B surface to get desired close surface.
• After that go to Part Workbench use Close Surface command to get thicken part.

ADD MATERIAL TO CLOSRD SURFACE

STEP 6 : CREATE DOG HOUSE WITH LOCATORS

STEP 7 : CREATE RIBS 

B-PILLAR WITH DOG HOUSE, SCREW BOSS, LOCATORS AND RIBS

STEP 8 : DRAFT ANALYSIS ON CLOSE SURFACE

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction. And move curser to part and select point and it shows the green color which represent the draft angle is 0.5 or above.

FINAL PRODUCT : 

TREE STRUCTURE

NOTE : 

The imprope tree structure and missing some images is due to I work this project in two different version.