Week 8 - Challenge 1 - Base Bracket Design

TASK: To create a Base Bracket Plastic component through the given Class-A surface.

Steps:

• download and open the class A surface given in the STEP file
• visualize the perfect tooling direction considering (x,y,z direction)
• create a tooling axis
• create class B surface
• create class C surface
• create a solid body

Visualizing the perfect tooling direction considering (x,y,z direction)

y-direction: this axis is only showing one section of the class A surface of the base bracket, this is NOT suitable.

x-direction: this would have been suitable, however, there is a hole that is not clearing. Creating a tooling axis will not be cost-effective as a different tooling axis will need to be created to form the hole. Hence, NOT suitable.

z-direction: this direction seems to be the perfect direction to create a tooling axis. All the sides and edges of the class A surface are clear and visible. In respect of this, a tooling axis WILL be created in the z-direction.

CREATING TOOLING AXIS

• create a dummy tooling axis at the z-direction
• create intersection lines in the z and y direction
• check the draft angle

Draft Analysis: a draft angle of a minimum of 3 degrees is created. To perform a draft analysis, View Mode Customization is set to Material.

Creating class B surface

• extract the surfaces on class A, extrapolate, trim, and offset to a distance of 2.5mm to form B surface.
• to attain even thickness, the dimension of the fillet in class A is added to the offset distance to form the dimension for the class B fillet.

Creating class C surface: this is created by sweeping the boundary of class A to intersect with class B.

• sweep the boundary of class A
• sweep the boundary of both holes
• join class A and the sweep for both holes
• trim class C with (class A, sweep for both holes)

Creating a solid body

• switch to part design workbench
• Click close surface
• select the trim surface