Challenge

A pillar Design with Master Section

MMithin Santhakumar6 Dec 2023

WEEK 11 - A PILLAR DESIGN WITH MASTER SECTION

TOOLING AXIS CREATION :

Tooling axis is the direction in which mould travels. basically there are two pieces for mould,one cavity side and one possess projections of the component. the draft angle given for the component for ease of ejection, is drafted with reference to this tooling axis.

conducted visual inspection initially, then checked for,if there is any gaps or corrections by taking boundary of the component.placing tooling axis perpendicular to the largest flat area of the component is more convenient for manufacturing. but for the given inputs, respecting the dog house, extracted side face lines of dog house from given master section and bisected. bisected line is selected as main tooling axis and proceeded to draft analysis to check for the validity of the tooling axis.

DRAFT ANALYSIS ON CLASS A

By performing draft analysis on the given class A surface enables to know wheather the component is easily removable or not and the tooling axis which we created is apt for manufacturing . this analysis is based on colour ranges which indicates different colours for different angles.

go to customize view parameter and select material mode in mesh
select feature draft analysis from analysis option by going in insert option from tool bar
place the compass align to tooling axis with the help of compass tool
select the surface
click display button on the window

for the given class A surface one edge is less than the nominal draft degree which is 3 degree.it is indicated by red colour

each colour zones indicates each drafting angles,green indicates within given draft angle , red indicates zero and blue indicates negative angle

CREATION OF CLASS B SURFACE

start with creating seperate geometrical set for class b, take an offset of the given class surface to a value of 2.5mm in inside direction. some patches would be there in the offsetted plane,most of the times,fillets are the cause of patches.

here, one curve face is missing .

it is resolved with the help of multisection tool. thus class B surface is obtained

CLASS C CREATION:

create boundaries at edges of class a
select sweep with draft direction from sweep option.
select the created boundary as guide curve and tooling axis as draft direction,with 3 degree angle projecting out from class a
follow above sweep procedure for planes which are perpendicular to tooling axis
for planes parallel to axis,sweep in 90 degree refence to the class a surface
extrapolate the ends of swept planes and trim altogether to get the c surface

always remember to give a 1 mm of second limit when sweeping,because it helps class c to trim properly with class a.

TRIMMED CLASS A & C

trimming class A,B & C gives final closed body

moving to part workbench, opting closed body tool and selecting our final trim obtains solid body

DRAFT ANALYSIS ON SOLID COMPONENT :

CREATION OF DOG HOUSE:

reference for dog house

PROCEDURE :

extracted the outlines of dog house from given master section
created a plane on the curve 2 parallel to the curve.
openend a positioned sketch on reference to the new plane and point on the curve
extracted outlines of the doghouse and iso constrained
extruded the sketch in shape workbench,perpendicular in direction to the plane
created a new plane on curve 1 parellel parallel to the same curve
opned a new positioned sketch on reference to the created plane
extracted other outlines of the doghouse from the given master section
extruded the sketch
trimmed both extruded surfaces
thickened the surface using thickening tool in part workbench
drafted and filletted the faces
offsetted the 2 sides and top inward to desired value
splitted the thickened object with this surafce.
drafted the splitted surface and filletted
union trimmed the part with partbody selecting the projected parts beyond the closed surface as faces to remove
opened another geometrical set
openend a new sketch as same reference of the first sketch
extracted the inside features of the dog house from the master section
extruded it perpendicular in direction to the plane
trimmed it with extruded front and rear surfaces of dog house,thus obtained a closed body
selecting closed body tool from part workbech made this trimmed surface to a solid body
union trimmed it with the part body selecting the projected parts beyond the dog house as faces to be removed
drafted to a value of 0.5 degree and filleted to value of 0.25 radius
created a new plane on the top surface of the dog house
opened a positioned sketch on reference to this new plane
created the drawing as shown on the given reference image of dog house with assumed values
extrude the sketch in shape work bench
splitted it with the closed body in part workbench
filletted the edges