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

Attachment Feature Creation (Ribs & Screw Boss)

OBJECTIVE:

• Develop the Door Handle Component from the provided Class-A surface.
• Establish the tooling axis for the Class-A Surface, ensuring it meets the draft angle requirements.
• Integrate B-side features into the component.
• Conduct a draft analysis of the model.

DESCRIPTION:

1. CREATING TOOLING AXIS:
• The tooling direction refers to the direction in which the mold separates. The mold consists of two parts: the cavity and the core side, which pull apart along the tooling direction.
• Ensure there are no gaps between surfaces by using the join function and previewing the results.
• Extract and disassemble the boundary.
• Identify the correct tooling axis where the material does not interfere, allowing all elements to be created.
• Create an axis system centered on the switch bezel.
• Intersect the yz plane with the class A surface.
• Hide the class A surface and create lines between points on the suspected drafts.
• Form a bisecting line using the two lines and a point to establish the tooling axis.
• Bisecting lines ensure the optimal draft angle by finding the exact midpoint between two sides.
• The tooling axis is created by bisecting two axes from the x and y planes.

2. DRAFT ANALYSIS:
• The draft analysis command checks if the drafted part can be easily removed from the mold. This analysis uses color ranges to identify zones on the element based on deviations from the draft direction.
• Before performing the draft analysis, customize the view parameters under mesh, check the material option, and confirm.
• To perform the draft analysis, go to Insert > Analysis > Feature Draft Analysis.
• Use the compass to define the draft direction.
• Set the draft angle to 3 degrees in the color scale.
• A green indication on the component shows a passing draft angle.
• Use a running point to verify the angle of the component.
• The draft analysis is now complete.

3. CREATING CLASS B SURFACE:
• Extract surfaces from class A using multiple extract and untrim them.
• Use Extrapolate to ensure proper intersection of untrimmed surfaces, then offset the surfaces by 3mm to create thickness.
• Trim the excess surfaces using the trim command.
• Insert the trimmed surfaces into a new geometrical set and label them with appropriate part names.
• Apply fillets to the model after the entire surface is created.
• Adjust the fillet value according to whether the edges are inside or outside the fillet.
• Perform trims one at a time for clarity.

4. CREATING CLASS C SURFACE:
• Extract the boundary from the class A surface using the boundary command.
• Use the disassembly tool to divide the boundary into domains.
• Use the sweep command with the following settings: profile type as line, subtype as with draft direction, guide curve and draft direction, and a draft angle of 3 degrees. Preview the result.
• Trim the sweep output with the class B surface to achieve the final output.
• Open the part design workbench and create a solid of the component using a closed-body surface.

5. CREATING B SIDE FEATURES:
• Rib Creation:
• Follow the design principles for rib creation.
• Sketch the necessary rib design.
• Screw Boss Design:
• Adhere to the design principles for screw boss creation.
• Sketch the screw boss design.

CONCLUSION:

• The tooling axis and CAD part with B-side features have been created from the given Class A surface, and the draft analysis has been successfully performed