Week 8 - Challenge 1 - Base Bracket Design

BASE BRACKET

Aim/Objectives: To make a model using the Class A Surface After extraction by using surface workbench

Introduction:

Class A Surface: An aesthetic & outermost surface which is made by the plastic designerand is given as an input to the plastic modeler to work on it.

Class B Surface: A surface below a certain thickness from the class A Surface is known as class B Surface. It is also known as engineering Surface.

Class C Surface: A Surface that Join the class A & Class B Surface.

Methodology: In this design we will focus on the following steps

1. Tooling Axis
2. Draft Analysis
3. Class B Surface
4. Class C Surface
5. Making a solid model from surface

Following tools were used to reach the final step:

1. Extract
2. Un-trim
3. Trim
4. Extrapolate
5. Offset
6. Edge fillet
7. Boundary
8. Sweep
9. Join
10. Close Surface (part design)

FOR TOOLING AXIS:

1. First we will take a point using circle/Ellipse
2. After we will draw a dummy tooling axis using point & direction
3. Intersect the YZ plane of the axis system with the input and we can see that there is no surface that can create problem during tooling in this direction.
4. Intersect YZ plane and we are unsure of these two surfaces, so we make a line and bisect them both and this will be our tooling axis

FOR DRAFT ANALYSIS:

1. Go to insert< analysis< feature draft analysis.
2. Align the tooling axis with the compass.
3. Click on the surface and see that the surface is within the permissible limit of the draft values.
4. The surface should be green and in the column proper value (3deg) should be inserted.

RIBS SURFACES:

1. Extract the rib surfaces (1 rib at a time).
2. Un-trim the surface.
3. Extrapolate it.
4. Offset it by 2.5mm i.e. thickness.
5. Trim to get the desired shape.
6. Repeat it with the second rib too.

FOR CLASS-B SURFACE:

We can divide the surfaces as shown below. Then we will work on them one by one

FLAT SURFACE:

1. Extract the flat surface.
2. Un-trim the surface.
3. Extrapolate it.
4. Offset it by 2.5mm i.e. thickness.

Once we have finished doing this, we have to trim the surface to get exact shape of the class-A surface (without fillet) below 2.5mm. After the trimming part is done, fillet the model. Formula for filleting= fillet value thickness (if the surface is below). We get our class-B surface.

FOR CLASS-C SURFACE:

1. Extract the boundary of the class-A surface.
2. Extract the boundary of the holes on the class-A surface.
3. Use sweep command on the boundaries one by one to get the class-C surface.

FINAL BASE BRACKET:

1. Join the class-A and class-C surfaces together.
2. Trim the class-B surface with the join created earlier
3. Go to part design and close the model.

Feature Tree:

Different Views:

1). Isometric View:

2). Top View:

3). Front View:

4). Left side view:

Coclusion:

Thus i've created the design of Base Bracket using Class A Surface using Surface Workbench.