Challenge

Week 10 - Challenge 1- Attachment Feature Creation (Ribs & Screw Boss)

Aim:

Creation of the rib & Screw boss for the Drill Handle considering the design rules.

Constructional Report:

Tooling Axis:

The direction in which the Mold or core and cavity opens is the tooling axis.
For Tooling axis creation, need to find the flat surface, extract it and create the point in its centre by Reference tool Bar. Create new Geometrical set as Tooling axis.
Then Create a Line through the point on Y Direction and extend it & highlight the line as per our convenience
Put the Class A surface in No material Mode in View tool bar.
Go to Insert ‎‎- > Analysis - > Feature Draft Analysis.
Click the Compass, drag the compass towards that line and place vertically along it and click lock button.
Select on any part of the surface then see some colour changes on it.
Select 3 degrees as green and check the surface it shows all as green , it means our created tooling axis is correct.

CLASS B:

Create new Geometrical set as Class B
CLASS B surface having all Engineering features likes ribs, Screw Bosses & Dog House.
For this we need Class A surface and need to Offset create a new geometrical set and offset it as per given Thickness 2.5 mm.
After Offsetting check the non-off-setted patchy surfaces, take boundaries and extrapolate that and make a trim.
After the patchy surface rework, check the boundaries on green not having any errors in the surface.
Take Overall Boundary of Class B surface and extrapolate it 10 mm.
Go to extrapolate tool in Operations tool bar, select the boundary and put in curvature continuity.
Now we created the CLASS B Surface.

CLASS C:

CLASS C surface provides the connectivity as already thickness we provided on class B surface with Class A surface.
Create a New geometrical set as CLASS C.
If our class C surface want Parallel means use the draft direction angle method.
If our Class C surface want in perpendicular means use the reference surface method.
We need to do create class C surface for two sides so using draft direction in sweep.
Select the boundaries of two sides and select sweep option then select draft direction option.
Select the curve and guiding tooling axis and give the value how much depth we want that curve for intersect our class B Surface.
For perpendicular creation, so we used reference method. Take another two sides boundaries & make a sweep as per our required depth.
Then join those sweeps and extrapolate in it edges wherever needed.
Do the trimming operations to get full body as a CLASS C surface in single surface.

CLASS A & C:

Now we have separate CLASS A & CLASS C surfaces. Create new Geometrical set.
So now we can join those class A and class c surface by using join command and give 0.003mm, which is the maximum deviation value we can provide to surfaces.
We have joined those surfaces now next will be trimming operation.

PLASTIC PART /FINAL PART:

Now trim our class A & C with class B surface to get the desired part. Create new Geometrical set.
Then define the part body and go to part design workbench, where select the close surface.
Select our final part, now thick part body gets created.

RIBS:

Now we have final part body, create a plane over the surface where we want to create ribs.
Create a point on the surface for projection purpose.
Create new Geometrical set and define it & select position sketch take plane as planar support & select point as a projection point in origin & reorder the orientation.
Sketch the ribs line and provide proper dimensions, make sure the sketch is iso constraints.
Select the Pad option and pad it 5 mm height up to 5t thickness of our part. Our part has 2.5 mm thickness so 5 X 2.5 =12.5 mm. Provide second limit also as 1mm inside our body, thick profile is selected as well and give 1mm as thickness as per norms 0.4 times of body thickness we can give for neutral thick body 2.5 X 0.4 =1 mm.
Give draft angle as 0.5 degrees and select neutral element as base plane pulling direction as Tooling axis.
Assemble it to our part body tree
By using these procedures, we create other ribs also and fillet those ribs of 25 mm as per norms.
Now our Ribs are created.

SCREW BOSS:

Create new Geometrical set and define it & select position sketch take plane as planar support & select point as a projection point in origin & reorder the orientation.
Sketch the Screw boss and provide proper dimensions inside dia 5.2 bolt size & onside of wall should 0.6 times of thickness so (0.6 X 2.5 X 2 = 3mm) and add bolt thickness (5.2 + 3 = 8.2 mm) outside dia, make sure the sketch is iso constraint it.
Pad it for 12 mm and secondary limit of 1mm inside the part body.
Fillet the bottom part of 0.25mm radius.
Then Create the supports of this screw boss need to create.
Select position sketch take plane as planar support & select point as a projection point in origin & reorder the orientation.
Create a line inside the middle and constrain it, dimensions of 20mm per line (10 +10) on both the directions in horizontal direction.
Also, for vertical direction same line was created.
Define in new part body and Pad It for 10mm height, secondary limit of 1mm & neutral thickness of 1mm.
Give draft angle as 0.5 degrees and select neutral element as base plane pulling direction as Tooling axis.
Make a union trim with Closed part body and remove the inside element.
Finally provide fillets of 0.25mm for all edges.
Copy the part file and make a paste special with link as result.
Move the part body wherever we want by using translation method and select coordinate option in translation.

Publication:

Publication is a future used to represent our specific surface or body outside from our mingled tree.
It is mainly used to represent bodies for easy selection purposes.

Tree Structure:

Result:

The ribs and screw boss were created and published as per the standards where the screenshots part files are attached with these reports for further reference.

Ship work like this
in your own course.