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.

Objectives:

• Creation of Tooling Axis.
• Creation of Class B and Class C surface.
• Creating a solid part out of surface modelling.
• Draft Analysis of Class A surface and final plastic component.

Tool Used: CATIA V5

Introduction: In this project we are designing a base bracket using given class A surface. The approach includes creation of Class B surface keeping 3 mm thickness in mind for the complete component. The design also included Class C creation from the given parent surface.

Constraints:

• NO CHANGES IN CLASS A ARE ALLOWED.
• PART THICKNESS CANT DEVIATE BY MORE THAN ±

• 30%
• ALL DESIGN RULES SHOULD BE STRICTLY FOLLOWED.
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID.
• ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS.

CLASS A: Following surface is given as the input for the component creation.

https://drive.google.com/file/d/1_608c_4qTC9nezf51-zEQ5PDfo9M-qoT/view?usp=sharing

To continue with the design process first we need to find out the tooling axis for the surface and check for all the drafts using Draft Analysis tool of CATIA.

Creating of Tooling Axis:

• Create an intersection of CLASS A surface with ZX plane and from the intersection create the tooling axis as shown below.
• Create a bisecting line using the lines shown .

Creation of Class B:

• Now for Class B creation, we have extracted surface from Class A and untrimmed them to obtain the original parent surface.
• These surfaces are then offset to the required thickness.
• After offsetting, all the surfaces are trimmed into the required shape.
• Required fillets are given to the surfaces.

Creation of Class C:

• For creating this surface we have extracted the boundry of Class A using multi-extract and then converted to smooth curve.
• Now this smooth curve is swept along the draft direction with a 3deg draft.

Class A + Class B + Class C:

For this we have trimmed the above shown surface with the Class B surface using trim feature.

Draft Analysis on the Final Component:

For this analysis, main tooling axis is taken draft reference.

Following results were obtained: