Week 8 - Challenge 1 - Base Bracket Design

Aim:

 To create the Base Bracket Plastic Component through the given Class-A Surface and to perform Draft Analysis on the final plastic component using CATIA V5 tool.

Objectives: 

• Creation of Tooling Axis with bisecting method.
• Creation of Class B and Class C surfaces.
• Creating a solid part from the surface using close surface feature.
• Perform draft Analysis of final plastic component.

Introduction:

 This project aims to create a base bracket using a given Class A surface. The approach includes creation of Class B and Class C surfaces keeping 2.5 mm thickness in mind for the complete component. 

Design Constraints:

• ALTERATION OF CLASS A IS NOT ALLOWED.
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID.

ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS.

Procedure:

• Class A surface

• Class A surface is used as the parent reference to begin the design of a product.
• To continue with the design process, we need to find out the tooling axis for surface-A.
• Next step is to check for all the drafts using Draft Analysis tool of CATIA V5.

•  Draft Analysis for Surface A

• The Drafting analysis is performed using the Feature Draft Analysis command from INSERT menu
• The drafting analysis is done with 3 degree draft angle.

•  Creation of Tooling Axis

• A dummy Tooling axis is created using a reference point created on a hole of the given surface.
• Create an intersection of CLASS A surface with YZ plane.
• Tooling axis is created from these two lines as shown in above image using Bisecting option.
• The central line shown in figure is the tooling axis.

•  Creation of Class B surface

• Class B surface is created from the Class A surface.
• Extract the surface from Class A using Extract command and untrimmed followed by Extrapolate if required, to obtain the original parent surface.
• The same procedure is followed on the other side as well.
• The resultant surfaces are then trimmed to form the Class B surface which is offset at a required thickness from Class A surface.
• Finally all the necessary fillets were added to the Class B surface.

•  Creation of Class C surface

• Class C surface connects the Class A and Class B surface.
• For creating Class C surface, initially the boundary of Class A is extracted using Boundary
• Then Sweep command is used along the draft direction, with a 3 degree draft angle.

•  Join Class A and  Class C

• The holes present in the surface are created using boundary command and Sweep command.
• To make Class A and Class C as a single body, both surfaces are joined using Join This command is used to make sure that there is no any open boundary between Class A and Class C.

•  Final trims:- Class A + Class B + Class C

• To obtain the final output, (shown in below figure) the joined Class A+C is trimmed with the Class B surface using trim feature.

• Solid body is obtained using closed surface feature from part workbench.
• The Tooling axis, Class A, B and C surfaces were published.

 

• Draft Analysis of the Final Component

• Main tooling axis is taken as the draft reference for this analysis.

Conclusion

Final output ‘”BASE BRACKET” is successfully published using CATIA VS tool.