Challenge

Week 8 - Challenge 1 - Base Bracket Design

RRajhansh Kumar24 Nov 2022

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.

NOTE:

Tree Structure Ensure Proper Tree Structure

Geometrical sets should have a proper name based on the sketches present inside of it

All the sketches should be created under the Geometrical set

Use the Close Surface feature to make a solid body from the surface.

Publications: Use the publication option and publish the below

Tooling Axis Class A, B, and C surface

Report –

Objective:

The main objective of this challenge is to create the Base Bracket Plastic component through the above-given Class-A surface, by giving the 'Tooling axis' and 'Draft analysis' to the class-A surface of the base bracket.

TOOLING AXIS:

We should keenly observe and study the class A surface to create the 'Tooling Axis' for the component, for the above-given base bracket Z-axis is the best suitable tooling axis. Initially, I created a dummy tooling axis on Z-axis by considering the reference point created in the middle of the circle.

DRAFT ANALYSIS:

To perform draft analysis, click on Insert >>Analysis >> Feature Draft Analysis

Once the draft analysis toolbar is opened, go to the display block and select the 'Analysis under the running point' command to check the angle for different sides (ribs and inclined plane angles) on the class A surface. The color scale on the bottom visualizes, whether the draft angle meets the requirements or not (3 deg) by indicating the colors Green, Blue and Red. Once the draft angle analysis was done, we need to align and fix the compass to the tooling axis of the class A surface.

To align and fix the compass to the tooling axis, go to the Direction block in the draft analysis toolbar and click on the 'Use the compass to define the new current draft direction option (or just click on the compass symbol). Now bring the compass to the surface and align it to the tooling axis of the class A surface and click on the lock symbol beside the compass in the direction block. Once we click on 'ok' on the draft analysis toolbar, we can finish the draft analysis process.

CLASS B SURFACE:

To create the class B surface, I considered the entire surface has 3 parts 'Rib-1, Rib-2, and Base surface'. If we directly offset the class A surface, fillets may lead to cause an error, to avoid the errors we need to extract the surfaces and untrim the extracted surfaces and extrapolate those untrimmed surfaces with point continuity. Now trim those extrapolated surfaces to the required shape. And finally, fillets were given to the final trim.

Rib-1 and Rib-2:

Base surface creation:

Class C Surface:

It is the combination of Class A, Class B and Class C surfaces. To create a class C surface, I used the sweep command by considering the outer boundary of the class A surface. In the sweep command, go to the 'line' command in the 'profile' block and the subtype is 'with draft direction'. Now select the outer boundary and tooling axis, give 3 deg in the angle (the draft angle for a plastic component is 0.5 to 3 deg) and select the direction to sweep, in this condition the class B surface is under the class A surface so select the inside down arrow to sweep. The same procedure is repeated for the two circles on the class A surface. Now I joined all the sweeped surfaces by using the 'join' command and then I trimmed the Class A, Class B and Class C surfaces to make a closed surface, to make a Solid body.

Boundary creation :

Sweep surface definition: