Challenge

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

LLokesh Thotapalem30 Mar 2023

Aim

1. To create the Door Handle Component from the given Class A surface

2. To Create the the tooling axis for the given Class A surface meeting the requirement of Draft angle.

3. To Attach B side feature in the component.

4. Create the rib for the Drill Handle considering the design rules

Description

1. Creating Tooling Axis -

The Tooling Direction is basically the basically the direction that the mold pulls a part. The mold is built in in two seperate pieces, basically . You have a Cavity side and you have the Cove side . The core pulls apart from the cavity and thats the Dye line or the Tooling Direction.

1. Open the given CAT part file.

2. Check for gaps between the surfaces for that click on join and then preview.

3. If theres any gap between the surfaces join them with a maximum tolerance of 0.003mm.

4. Extract the boundary and dissemble the boundary.

5. Find the correct tooling axis where the material dont interfer with the tooling axis and all the elements can be created .

6. Created an axis system using at the centre of the switch bezel.

7. Intersect the yz plane with respect to class A surface.

8. Hide the class A surface and create point to point lines on the suspected drafts.

9. Create bisecting line with the two lines and point to create a tooling axis.

10. BISECTING LINES were used to get the exact medium from the two sides so that maximum positive draft angle can be achieved.

11. The Tooling axis is created the component by bisecting two axis from x and y planes.

Publication

1. Publication is done to the component to make it visible and navigate easily.

2. To publish the component go to tools , publications and then select the tooling axis and the class A surface.

3. A separate tree structure is formed under the main part.

Draft Analysis

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 value.

1. Before going to draft analysis go to customized view parametre> under mesh> check material and then click ok.

2. Now for Draft analysis go to insert>> analysis >> feature draft analysis.

3. Use the compass to define the draft direction.

4. In the colour scale change the draft angle to 3degree.

5. The component changes to green in indication of passing draft angle.

6. Use running point to check the angle on the component.

7. The draft analysis is complete.

Creating Class B surface

1. Extract the surface from the class A using multiple extract and untrim them.

2. Use extrapolate to make sure that all the untrims are properly intersected to trim and offset the surface to 2.5 mm to create the thickness.

3. Trim the extra surfaces using trim command.

4. Insert them into new geometrical set and name it with respective part names.

5. Apply fillets to model after creating the entire surface .

6. If the edges are outside the fillet value will added to the thickness of the component and if the edges are inside , the fillet value will will be subtracted from the thickness of the component , for instance the thickness of the component is filleted is 2.5mm the fillet value is 15 mm so the outside portion value should be 17.5mm and inner eges should be filleted 12.5mm to get uniform thickness.

7. Perform trims one at a time so that it will be clear to understand.

Creating Class C surface

1. Extract the boundary from the class A surface using boundary command .

2. Using disassemble tool to divide the boundary as the boundary contains domains.

3. Use sweep command> choose profile type line > subtype as with draft direction > choose guide curve and draft diretion > draft angle as 3 degree > preview.

4. After getting sweep them the output with class B surface to get final output.

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

B Side Features Creation

Rib Creation

Design Principle for Rib Creation

Sketch Used For Rib Creation

RIB

Screw Boss Design

Design principle for Screw Boss Creation

Sketch Used for Screw Boss Creation

Screw Boss

End Draft Analysis