Challenge

Week 8 - Challenge 1 - Base Bracket Design

RRaghupathruni Venkatesh26 Jun 2022

Objective: The main objective of this challenge is to create the Base Bracket Plastic component through the above-given Class-A surface, by giving the 'Tooling axis' and 'Draft analysis' to the class-A surface of the base bracket.

TOOLING AXIS:

We should keenly observe and study the class A surface to create the 'Tooling Axis' for the component, for the above-given base bracket Z-axis is the best suitable tooling axis. Initially, I created a dummy tooling axis on Z-axis by considering the reference point created in the middle of the circle.

Now, I intersected the base bracket on Z-axis by considering the reference of the 'plane.1'. 'Plane. 1' is created by taking the reference of the 'YZ plane' and 'point.1'.

Now, I created two lines on the intersection to create the main tooling axis by 'bisecting' those lines.

DRAFT ANALYSIS:

To perform draft analysis, click on Insert >>Analysis >> Feature Draft Analysis.

Once the draft analysis toolbar is opened, go to the display block and select the 'Analysis under the running point' command to check the angle for different sides (ribs and inclined plane angles) on the class A surface.
The color scale on the bottom visualizes, whether the draft angle meets the requirements or not (3 deg) by indicating the colors Green, Blue and Red. Once the draft angle analysis was done, we need to align and fix the compass to the tooling axis of the class A surface.

To align and fix the compass to the tooling axis, go to the Direction block in the draft analysis toolbar and click on the 'Use the compass to define the new current draft direction' option (or just click on the compass symbol). Now bring the compass to the surface and align it to the tooling axis of the class A surface and click on the lock symbol beside the compass in the direction block. Once we click on 'ok' on the draft analysis toolbar, we can finish the draft analysis process.

CLASS B SURFACE:

To create the class B surface, I considered the entire surface has 3 parts 'Rib-1, Rib-2, and Base surface'. If we directly offset the class A surface, fillets may lead to cause an error, to avoid the errors we need to extract the surfaces and untrim the extracted surfaces and extrapolate those untrimmed surfaces with point continuity. Now trim those extrapolated surfaces to the required shape. And finally, fillets were given to the final trim.

Rib-1 and Rib-2:

Base surface:

Class C Surface:

It is the combination of Class A, Class B and Class C surfaces.
To create a class C surface, I used the sweep command by considering the outer boundary of the class A surface.
In the sweep command, go to the 'line' command in the 'profile' block and the subtype is 'with draft direction'. Now select the outer boundary and tooling axis, give 3 deg in the angle (the draft angle for a plastic component is 0.5 to 3 deg) and select the direction to sweep, in this condition the class B surface is under the class A surface so select the inside down arrow to sweep. The same procedure is repeated for the two circles on the class A surface. Now I joined all the sweeped surfaces by using the 'join' command and then I trimmed the Class A, Class B and Class C surfaces to make a closed surface, to make a Solid body.

Boundary:

Sweep:

Class C surface:

Final Trim (closed body):

SOLID-BODY:

To create a solid body from the closed surface, I used the 'closed surface' command in part workbench. Click on the closed surface command in part workbench and select the final trim of the closed body and click ok. The required solid body is created by using the closed surface.