Week 8 - Challenge 1 - Base Bracket Design

Week 8 - Challenge 1 - Base Bracket Design

OBJECTIVE:-

The objective of the project is to design the Base Bracket and to do a draft analysis for it by creating the required tooling direction with the help of Bisecting method.

BASE BRACKET DESIGN

To create a closed solid body by using the given Class A surface and analysis the draft for the same.

Steps followed

• Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
• Connectivity of the surface can be done by two ways by join method and by boundary method.
• In the case of Class A the surface below is called core and the surface above is called cavity.
• Split the surfaces in to three profiles then Identify the surface which is not possible for tooling axis and check which direction is best fit for tooling axis and define the draft direction.
• First create a dummy tooling axis which is in concentricity with the hole.
• Create the tooling axis using the intersect method by creating a bisecting line.

Tooling Axis

• The direction in which the mould open and closes is the tooling axis.
• Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
• While creating a tooling axis give the tooling axis on a flat length surface or the surface which have a hole on it.
• Create a point on the surface where we are going to create the dummy tooling axis and using line command crate an axis. If there is a circle or flat length surface which is recommended.
• Bisecting method
• Identify on which plane we have to do more operations on surface and create that plane on the component area define it on the dummy tooling axis direction.
• And then intersect the class A surface with that plane then we will get a intersection sketch.
• Look for the profile (inclined line) which will create a problem and extending it by using line command.
• Then create a bisecting lines with reference to the lines we have extended and this will be our tooling axis.

Draft analysis

• Draft allows for the component to release from the mould, most parts or applications require a minimum of 0.5 to 1 degree draft angle and 3 dgree draft angle is widely used as per the norm.
• Change the material mode to customize mode before moving to the draft analysis.
• Insert –analysis-feature draft analysis
• Defining the draft direction Select draft analysis from the tool bar and click on the compass symbol and pull the compass from the right side top corner of the workbench and place it on the component where want to do the draft analysis. ‘W’ of the compass and tooling axis should be aligned on the same line.
• By clicking the on the surface and using the flipping tool we can assign the Flipping direction .
• Click on the lock symbol and click on the component then a table will appear it shows the draft value.
• Analysis under running point and move the mouse on the surface and it will show the details of the surface deg direct.

Creating B surface

• B surface should be inside the class A surface.
• Class A is an aesthetics surface and class B is an engineering surface.
• B surface can be created by three steps by ribs and the base.
• First step is to create the Ribs by extracting the required surface from Class A and untrim it thus we will get the six individual surfaces and extrapolated all and trim it to get the required shape and finally offset it by the required thickness.
• Then create the base surface by selecting the class A by extracting, offsetting and untrim then extrapolated and offset it.
• The final geometry of B surface is to trim both the ribs and again trim it with the base surface and all together.
• Fillet is given to the required surfaces by measuring the fillet value from the class A surface and the offset value of class B surface.

Creating C surface

• C surface has been created from with reference to the boundary lines of class A surface and sweep it with reference to the tooling axis then the holes are created by following the same method.
• Then join C surfaces and holes with class A surface.
• Finally trimmed the join with B surface to get the final compenent.
• By using the final Trim Create the solid body by using close surface on part workbench.