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

Objective: The main objective of this challenge is to create the B-side features RIBs and Screw Bosses for a given drill handle.

Tooling Axis:

To create the tooling axis, I extracted the surface of class A with no propagation and I created the point at the centre of the extracted surface and created a line at that point in the Y direction. After creating the Tooling axis, I performed a draft analysis for class A to check the draft angle for it.

Draft analysis :

To perform the draft analysis in class A, I selected the featured draft analysis tool in the Generative shape design workbench. Initially, I click on the 'use of the compass to define the new current draft direction' command to align the compass to the tooling axis.

Once the compass is aligned the compass to the tooling axis, we need to select the surface to perform draft analysis.  Class A surface will be highlighted (in green colour) according to the colour bar angle and colours we defined in it.

Here I gave green colour for > 3 deg, red colour for < 0deg and BLUE colour for less than 3deg and greater than 0deg.

Class B surface Creation: 

To create the class B surface for the door handle, I offset the class A surface to 2.5mm inside. Once the class A surface is offset created, according to the thickness, we can observe some patches on the offset surface due to the fillets on the class A surface. Now, we need to close those patches. I used multi-section solid command to close the patches.

Class C Surface creation:

I used the sweep command in the geometric shape design workbench to create the class C surface.

Initially, I extracted the edges of the class A surface with tangent continuity by using the multiple extract command. After extracting the class A surface edges correctly, I sweeped the extracted edges with 93deg toward the class B surface. After sweeping the extracted class A surface edges, I extrapolated the edges of the sweep for 2mm to intersect the sweep edges with each other. Now I trimmed the extrapolated surfaces together to create a complete sweep surface towards the class B surface. I joined both the trimmed sweep surface and class A surface together, to get the class A+C surfaces as a single surface. Now, to create a solid body for the door handle we need a closed surface. I trim the class B surface with joined class A+C surface to make the closed surface of a door handle.

CLOSED SURFACE: 

To create the solid body I used the closed surface command in the part workbench. Click on the closed surface command in the part workbench and give the closed surface as an input to create the solid part body.

RIB Design:

To create the ribs on the solid part body,  we need to follow the above-mentioned design guidelines. Initially, I create a line sketch for the rib and I extruded it in the tooling axis direction and I thicken the extruded surface to 1mm toward the inside,

after thickening the extruded surface I gave 0.5deg of draft angle to the rib, and I union trim the rib with the part body to remove the extra surface of the rib, by union trimming the rib with the part body the rib gets added to the main part body without the unwanted extra part. After adding the rib to the part body, I gave the fillet to the rib with a radius of 0.25mm (as per the design parameters 0.25mm is the maximum fillet radius). In the same way, I created the rib-2.

SCREW BOSS Design:

To create the screw boss, I created the circular sketch in the sketcher workbench and I padded the sketch to 12.5mm. Now, I drafted the inside and outside surfaces with 0.5deg in the tooling axis direction. After creating the screw boss, I gave 0.25mm of the fillet to all sides. Now, I translated the screw boss toward the right side for 35mm. To keep the screw boss stiff and rigid, I created 4 supporting ribs for each screw boss.