Week 8 - Challenge 1 - Base Bracket Design

1. Objective:

Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. With thickness of Plastic Part - 2.5 mm

2. Definitions

Class-A Surface:

Class A surface is made from scanned data with different software like allias etc.. lass A surface having CURVATURE CONTINUITY

Class-B Surface:

Class-B surface having all features(Rib,boss,snap etc). It is created by extracting the all wall of the Class-A surface.

Class-C Surface:

Class-C Surface is used to joining the Class-A Surface & Class-B Surface. This surface is generated by sweeping the Class-A surface boundary.

Draft Analysis

The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line

Tooling axis

Tooling axis is tells about the in which direction core should be move. This tooling axis creating by bisecting method.

3. Procedure

3.1 Tooling axis making

• Created a point on center of the circle on slant surface
• Creating a line from the point line in Z-Direction and named as Dummy Tooling axis.
• Plane was crated from the point and YZ plane as a reference.
• Intersecting the Class A Surface with plane-1
• Created a lines by taking intersecting lines as a reference, and then bisecting those with line and named as tooling axis.

3.2 Draft analysis for Class-A Surface.

• Insert--->Analysis--->Feature Draft Analysis
• Draft analysis window will appeared. In that using the compass and define the new current draft direction.
• Locked the draft direction.
• And then click on the surface.
• Color coded on the surface with reference to the draft angle.

Green for 3°,

RED For 0°

Blue for Below 0°

3.3 Creating Class-B Surface

• Extracted the surfaces from the class-A surface.
• Hide the class-A surface
• Surface untrimmed for all surfaces
• Extrapolated the all surfaces with point continuity.
• Trimmed as class-A surface
• Offsetting with 2.5mm

3.4 Creating Class-C surface

• Taking boundary from class-A surface
• Sweep the boundary with draft direction as tooling axis and draft angle 3°

3.5 Joining the Class-A, B & C surfaces

• Trim the Class-C surface with B-surface.
• Joined the class-A, B & C surfaces.

3.6 Solid model creation.

• Joined surfaces converted in solid model by Close surface command

3.7 Draft analysis for solid model.

• Insert--->Analysis--->Feature Draft Analysis
• Draft analysis window will appeared. In that using the compass and define the new current draft direction.
• Locked the draft direction.
• And then click on the surface.
• Color coded on the surface with reference to the draft angle.

Green for 2.5°,

RED For 0°

Blue for Below 0°

4. Result

Initially Tooling axis was created by bisecting method. And the draft analysis is applied for class-A surface. After that Created the Base Bracket Plastic component through the given Class-A surface with 2.5mm thickness. Now draft analysis is applied for plastic component of brace brace bracket and draft direction was found satisfactory.