Week 8 - Challenge 1 - Base Bracket Design

Requirement:- Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Checkpoints

1) To check the continuity of Class A surface
2) Find the tooling Axis of the component
3) Making B surface
4) making C surface
5) combining surfaces and creating closed body

Definitions:-

Class A surface:- Class A surfaces are those aesthetic/free-form surfaces, which are visible to us (interior/exterior), and have an optimal aesthetic shape and high surface quality.


Tooling Axis:- The direction in which the mold or core and cavity opens is the tooling axis.


Steps to work

STEP1

Initially check the connectivity of the surface, this can be done by creating boundaries or by simply using the join option such that any openings can be easily visualized.

Tooling Axis creation:

Using the tooling axis created along the x and y-axis, these tooling axes are used for the creation of the tooling axis by a bisecting method where the two lines and point will be selected as inputs.

We check the best possible tooling direction (X,Y,Z ) and find where all faces can be represented using tooling Axis

After choosing the particular direction we create Intersection points on the remaining axis were we get mean point to create the tooling axis.

This intersection can be done by Axis system or thru creating a plane.



The above figure shows the intersection with plane with dummy tooling axis

Then we create line reflecting the surface which are difficult to visulize for the direction (parallel to axis faces ) . As parallel surface might get not clear but perpendicular face get cleared as they reflect on the surface direction.





Now we create a Bisecting Line with two line and point to get the output line (Tooling Axis).

STEP 2

Draft Analysis:

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

Compass is used to define the draft direction.
If the minimum draft 3 degree is provided the whole component changes in to green colour





STEP 3

B Surface


Now for creating the B Surface we split the component into 3 parts Base , ribs (1,2) By using Extracted Surfaces and then Un trim them along with Extrapolation upon requirement Them trim them to get Final output required surfaces.



Base Surface, RIB 1, 2



Final B surface After triming

the filleting on the surface is given according to measurement using measuring Tool and also considering the thickness inside and outside surface

STEP 3

C surface

For making C surface initially we used the Boundary on the Class A surface



After Swept along downside as follows


Same Followed for the Holes On the Class A we have Two Holes on the surface took Boundaries of iT and swept along




Now we have used Join tool to combine both Hpoles with the Body and finally we can see the Join from the Inside view Below



Now Using trim tool we combined B and C surface to get the final Closed Body


Before Trim


After Trim


Now using the Closed Surface command in part design created a solid Body !



Tree Structure