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OBJECTIVES To improvise the Class A surface by resolving bad patches and adding flanges to it. To create A pillar solid model with the help of improvised class A surface. To create B side features for the A Pillar using the master section given to us as an input. To create main and side core tooling axis for…
Mukesh Kanna S
updated on 24 Sep 2022
OBJECTIVES
INTRODUCTION
MASTER SECTION: Master sections development takes place during feasibility check and concept validation stages of the product life cycle. These are typically the guides for design requirements and which decides the component packaging after the development of the concept design, i.e class A surfaces.
Master section helps us to decide the feasibility of the concept design, the clearances, the packaging and the fixation strategy of a component before converting the concept design into a solid 3D engineering design.
During the period of vehicle concept design the evaluation of the master section performance depends mainly on the reference vehicle data and experience of structure design engineer.
DRAFT ANALYSIS OF CLASS A SURFACE
CLASS B SURFACE CREATION
We need a thickness of 2.5mm for the A PILLAR so in order to create the class B surface we'll give an offset value of 2.5 mm to improvised class A surface.
After applying the offset command we'll see some of the patches of the resulting surface are not generating so we have to recreate those patches by using multi-section surface command.
On joining the recreated patches with the offseted surface we'll get the class B surface.
CLASS C SURFACE CREATION
Extract the side edges, front edges and rear edges of the improved class A surface and use sweep command using "with refrence to draft" option and make the draft angle equal to 3 degrees.
For the rest of the edges use multi-section surfaces command to make surfaces inline with the major surfaces created through sweep.
Join all the surfaces together using join command.
SOLID BODY CREATION OF THE A PILLAR
Using the Trim command join the class A surface with class C surface.
Trim the resulting Trimmed surface with class C surface.
The resulting trim we'll get is the closed shell body of A pillar.
Finally use closed surface command in the part design workbench which would lead the shell body into a part body.
CREATION OF MAIN AND SIDE CORE TOOLING AXIS
Apart from A surface and C surfaces we also need to consider the B side attachment features in order to create the tooling axis because all the attachment features have a large number of surfaces parallel to the tooling direction.
For creating the tooling we can take reference from the master sections of the B side features and create tooling axis accordingly as shown in the figures below.
There are some of the attachment features like doghouse that needed a side core during moulding operation so for such B side features we have to create a side core tooling axis.
For the creation of side core tooling axis again we can take refrences from the master sections of the A pillar. This is shown in the figures below.
DRAFT ANALYSIS OF SOLID BODY
CREATION OF B SIDE FEATURES
DOGHOUSE: Dog house are basically used to avoid sink marks on the A surfaces, specially at those regions where other attachment features like screw boss is attached, placing such features would add the thickness of the component at that particular region and this would leads to non uniform cooling of the molten platics during moulding resulting to shrinkage of the material from the outer side.
The creation of doghouse is done completely using the master sections, first we create sketches by taking the refrences from the master section and then we applied the extrude command so that we would get the wall surfaces of the doghouse. make sure we extrude the sketches along the direction of side core tooling axis.
similarly create the back surface of the doghouse by taking reference from the master section. After that we can use the trim command to give them a basic shape of the doghouse.
Add material to the trimmed surface by using the thicken command in the part design workbench. Make sure we give thickness according to the doghouse master section.
We can further use split command to split the extra or unwanted material portion and give proper shape to the doghouse according to the master section. We also need to use the split command to reduce the thickness of the doghouse from the bottom i.e 3mm to 6mm upward from the bottom edge touching the B surface.
The thickness to be reduced should be not less than 40% of the wall thickness.
Make sure that each face of the doghouse is drafted to a value of 5 degrees and these faces needs to be drafted by keeping mind their respective tooling axis along which they would be tooled.A minimum fillet value of 0.25mm is also required to all the edges.
Use pad command to check on the thick checkbox to thicken the profile with 1.5mm thickness value. Make sure the pad length is long enough to cross the doghouse top wall.
Give proper draft of 0.5 deg to all the faces.
DRAFT ANALYSIS OF DOG HOUSE
VIEWS
TREE STRUCTURE
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