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

Step 1: The entire Class A surface was analyzed properly for any surface discontinuities and other irregularities.

Step 2: Creation of Tooling Axis:

• A particular surface was identified as a potential surface on top of which the tooling axis was to be created.

• A point was taken on this surface and a plane was created at this point with reference as xy plane.
• The intersection of the Class A surface and this plane was done which resulted in this profile:
• Now two lines were made with line type as Point-Point with the help of the points obtained after the intersection.
• Bisection of these lines was made.
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• Now daft analysis was done with reference to this line.
• This was clearing most of the surfaces. So this is the tooling axis.

Step 3: Creation of Class B surface.

• An offset of Class A was taken just above it with a value of 2.5 mm.
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• The missing patch was fixed using the Multi-sections Surface command, and the entire surface was extrapolated 2 mm.
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Step 4: Creation of Class C surface.

• The boundary of Class A was swept part by part with a draft of 3 degrees for the bottom boundaries and 90 degrees for the top boundaries.
• Then all of these individual swepts were joined together.
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Step 5: Creation of Class A+C

• Class A and Class C surfaces were joined together.
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• Step 6: Class A+C and Class B were trimmed together.
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Step 7: Now this final trim was converted to a solid body using the Close Surface command.

Step 8: Creation of Ribs.

• A line was made on the extracted surface i.e mentioned in Step 2. And it was extruded by 12.25 mm and then thickened it by 1 mm.
• A similar rib was made which is at a distance of 24 mm.
• These two ribs were added to the main solid body using Union Trim.
• Draft was given to them.
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• Fillet of 2.5 mm was provided

Step 9: Screw Boss

The following sketch was made on the same extracted surface.

• This was extruded by 12 mm.
• Draft was provided to both outside and inside.
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• A same screw boss was made on the same extracted face.
• Fillet of 2.5 mm was provided
• These two ribs were added to the main solid body using Union Trim.

Draft analysis :

The ribs and screw bosses were clearing the given draft of 0.5 degrees.

Rib root thickness analysis:

Rib root thickness should not be more than 30% greater than the wall thickness.

The rib root thickness is within 1.3 x of the thickness of the main body. This is appropriate.

Conclusion:

The design part body and its engineering features were following all the design rules mentioned.