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

1. CREATING TOOLING AXIS -

The Tooling Direction is basically the direction that the mold pulls a part. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dye line or the Tooling Direction.

• Open the given CAT part file.
• Check for gaps between surfaces for that click on join and then preview.
• If theres any gap between the surfaces join them with a maximum tolerance of 0.003 mm.
• Extract the boundary and dissemble the boundary.
• Find the correct tooling axis where the material don't interfere with the tooling axis and all the elements can be created.
• Create an axis system using at the centre of the switch Bezel.
• Intersect the yz plane with respect to the class A surface.
• Hide the class A surface and create point to point lines on the suspected drafts.
• Create bisecting line with the two lines and point to create a tooling axis.
• BISECTING LINES were used to get the exact medium from the two sides so that maximum positive draft angle can be achieved.
• The tooling axis is created for the component by bisecting two axis from x and y planes.

3. DRAFT ANALYSIS FOR CLASS A

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

• Before going to drat analysis go to customized view parameter >under mesh >check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compasss to define the draft direction.
• In the colour scale change the draft angle to 3 degree.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.

Darft analysis is a tool perform to check the product easliy removed from the core and cavity.

In this project we analysis the draft angle of the Class A Surface And the plastic components with feature.

In the draft analysis of Class A surface of door handle, most of surface are green that means the surface has draft angle more than 2.9 degree and some surface has draft angle in between 3 to 1 degree which is shown in blue color and there is not negative draft surface here.

4. CREATING CLASS B SURFACE

• Extract the surfaces from the class A using multiple extract and untrim them.
• Use Extrapolate to make sure that all the untrims are properly intersected to trim and offset the surfaces to 2.5 mm to create the thickness.
• Trim the extra surfaces using trim command.
• Insert them into new geometrical set and name it with respective part names.
• Apply fillets to the model after creating the entire surface.
• If the edges are outside the fillet value will be added to the thickness of the component and if the edges are inside, the fillet value will be subtracted from the thickness of the component, for instance the thickness of the component Is 2.5mm the fillet value is 15mm so the outside portion value should be 17.5mm and inner eges should be filleted 12.5mm to get uniform thickness.
• Perform trims one at a time so that it will be clear to understand.

5. CREATING CLASS C SURFACE

• Extract the boundary from the class A surface using boundary command.
• Using disassemble tool to divide the boundary as the boundary contains domains.
• Use sweep command > choose profile type line > subtype as with draft direction > choose guide curve and draft direction > draft angle as 3 degree > preview
• After getting sweep then trim the output with class B surface to get final output.

• Now open part design workbench and using close body surface create a solid of the component.

RIB CREATION

Rib provides an economical way to increase stiffness and strength to the mould parts without increasing the overall thickness of the wall. It is thin protrusion that extended perpendicular from the wall.

SCREW BOSS

Screw boss are used as a point for attachment and assembly, most common in as cylindrical projection with hole design to receive screw or other types of fastening hardware.

FINAL DRAFTING ANALYSIS:

The draft analysis at draft angle 0.48 degree with the tooling axis to the plastic componenets engineering feartures like Rib and Screw boss show green which means it clear during production process, but some surface of left side of Class-C surface has negative draft upto -0.73 degree which show in red color.

TREE STURCTURE