Challenge

Week 8 - Challenge 1 - Base Bracket Design

AIM

To create a Base Bracket Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component.

OBJECTIVE

CLASS A SURFACE

Class ‘A’ surfaces are primarily used in the automotive environment and refer to those surfaces which are visible in a product. In other words: A - class surfaces are those aesthetic/free-form surfaces, which are visible to us (interior/exterior), and have an optimal aesthetic shape and high surface quality.
The surfaces or regions which are visible nowadays are considered for Class-A modelling. It is one of the reasons why the importance of Class-A modelling is increasing day by day. Majority of the time this term is used in Plastic Part designs.

CLASS B SURFACE

The Class B surface is created from the Class A surface, keeping the thickness of the component in check.
The Class B surface resembles an offsetted surface from the Class A.

CLASS C SURFACE

The Class C surface is used to bind the Class A and Class B surface together in order to form a closed surface.

PROCEDURE

Creating Tool Axis

Initially the given Class-A surface was imported and checked for any discrepancies in the boundary and performed draft analysis on it at 3-degree draft.
A dummy Tooling axis was created using a reference point created on a hole of the given surface.
Create an intersection of CLASS A surface with ZX plane. The lines which might cause trouble during the operation were identified and a reference line was created for each of the identified lines.

Finally, a Tooling axis was created from these two reference lines using Bisecting option.

Creating Class B surface

Initially the ribs were created from the Class A surface.
The required surfaces were obtained from the Class A surface using Extract command.
These surfaces were further expanded using Untrim and Extrapolate commands
The protruding surfaces were trimmed using the Trim command and a proper continuous surface was obtained.

The same procedure was followed for the middle flat surface and surrounding area.

These surfaces were offsetted according to the required thickness of the component.
Finally filleting the edges of class B surface considering thickness value to it.

Creating Class C surface

The Class C surface connects the Class A and Class B surface.
Initially the outline of the Class A surface was obtained using the Boundary command.
The Sweep command was used along with draft direction, with a draft angle of 3 degree.
Further the holes presented in the surface were created in the same manner.
All the swept surfaces were finally attached to the Class A surface using the Join command.
Further the holes presented in the surface were created in the same manner.

All the swept surfaces were finally attached to the Class A surface using the Join command and obtained as CLASS C surface

Creating Solid Body

Later, CLASS C and CLASS B surfaces were trimmed and forms the base bracket surface.

Using the surface created, the solid component was obtained using the Close surface feature present in the part workbench.

DRAFT ANALYSIS

First, we should change model into material mode
Go to insert and in analysis select feature draft analysis
Align the compass along tooling axis
Next click on the surface and see that the surface is within the permissible limit of the values
The draft angle should be 3 degrees.

On given Class A surface

On obtained PART BODY

EXPANDED TREE STRUCTURE

CONCLUSION

Ship work like this
in your own course.