Attachment Feature Creation (Ribs & Screw Boss)

WEEK 10 CHALLENGE 1 : ATTACHMENT  FEATURE CREATION (RIBS AND SCREW BOSSES)

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. so, extracted largest face of the given class A and placed a point on middle of the surface.created axis through this point perpendicular in direction. 

DRAFT ANALYSIS ON CLASS A SURFACE

                                                                 By performing draft analysis on the given class A surface enables to know wheather the component is easily removable or not. 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

green zones indicates faces within draft angle,red indicated zero inclination and blue means negative inclination.

CREATION OF CLASS B SURFACE 

•   create a geometry set for class b surafce
• extract each faces seperately
• untrim each extracted faces and untrim them
• offset each planes to a value of 2.5 mm which is the thickness of the component
• hide the parents of the offsetted planes
• extrapolate each planes to suitable values with point continuity propogation and curvature continuity.
• trim all the planes together. take simple  trims,dont try to accompolish whole trim in single shot                          
• give fillets to the appropriate corners
• if the curve is concave to the inner of component,add thickness value to the radius and if it is convex, deduct thickness value

after offseted and extrapolated all faces

after trimming

after filleting,class B

CREATION OF CLASS C

•   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

class c

trimming A,B and C surfaces together results in final component

ATTACHING RIBS :

SKETCHES USED IN RIB CREATION :

intersection of component through ribs

SCREW BOSS ATTACHMENT :

design rules of screw bosses

sketch used for screw bosses

screw boss is designed for a M6 bolt , D as 5.2mm 

intersection through screw boss indicating rib root thickness,

DIFFERENT VIEWS OF FINAL COMPONENT

DRAFT ANALYSIS ON FINAL COMPONENT.

Red indicated faces has zero degree inclination and which would be little complicated to manufacture because these parts wont eject easily.

A surface need to be reworked to resolve this