Week 8 - Challenge 1 - Base Bracket Design
BASE BRACKET DESIGN - CLOSED SURFACE FEATURE
AIM:
To create a Base Bracket Plastic Component using a Class 'A' Surface and by using the Closed Surface Feature to create a solid part from the surface.
OBJECTIVE:
- To Create a Plastic Component using the Class 'A' surface.
- To create a Tooling axis for a class 'A' Surface, which meeting the requirement of the draft angle and to analyse the solid model.
- To create a solid model from the surface using the Closed Surface Feature.
- To create a report which explains the Draft analysis and Tooling Axis cration and colour scale varient.
- To attach the screenshots of the expanded Tree Structure for the Geometrical Sets .
- To attach the screenshots of the 3D Part Model in different orientations.
PUBLICATION:
- Class 'A' Surface.
- Tooling Axis.
- Class 'B' Surface.
- Class 'C' Surface.
INTRODUCTION:
TOOLING DIRECTION:
The Tooling Direction is the direction that the mold pulls apart. The mold is built in two separate pieces,
- A Cavity side and
- The Core side.
The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction. The direction in which the mold or core and cavity opens is the tooling axis.
FEATURES OF TOOL:
- Cavity half – The cavity half is the side of a tool that does not move. It is typically attached to the side of the molding machine.
- Core half – The side of the tool that opens and closes with the mold machine against the cavity half. It opens when removing the part from the tool.
- Cooling lines – Channels that allow coolant to flow throughout the tool and control the cooling of the plastic part.
- Ejector system – Pins on the core half of the tool that helps push the cooled part out after molding.
- Runner – A flow path for the plastic resin allowing the press to inject material directly into the part cavity.
- Side actions – Moving pieces within the part cavity added to allow for undercuts.
CATIA 3-D SURFACE SOLID PART MODEL - CLOSED SURFACE FEATURE
DESIGN CHECK:
The Class A Surface are Checked Visually by using the Join Feature or by using the boundary feature the Class A surface are selceted and Disassembled the Surface to check the surface are created without the gaps.
The Class A Surface should be created without the boundary Gaps. By using the Join Definition with the Merging distance of 0.001 mm the Class A surface are Joined Together to check the connectivity.
PUBLISHING THE CLASS A SURFACE:
By using the Publication option the Class A Surface are Published. The Publication is used to retrive the Class A surface in the easier way to use from the Structured Tree Implementation.
CREATING TOOLING AXIS:
The Tooling for the Class A Surface are Created in the diection in which the parts are getting Ejected from the Tool. The Tooling Axis which defines the core and cavity pulls apart from the Tooling Direction.
By using the Point Definition, The point has been created on the circle midpoint.
The Reference Tooling Axis has been created using the line definition feature. From the line type point direction, Point has been selected and direction along z component are selected to define the line.
By using the Plane Definition the planes are created from the yz plane and moved through the point created from the origin.
By using the Intersection feature, the first element and second element are selected. The first Element Class A surface are selected and for the second element Plane are selected.
From the Intersection to the plane created. By using the line Definition, point - point type are selected and from the intersection Points, Line type 1 are created and another point - point lines are created.
The Two lines are created from the intersection, The lines are created which makes or slightly parallael to the Reference Tooling axis.
BI- SECTING METHOD:
By Using Line Type Bisecting, The Main Tooling Axis are created by selecting the Parallel Lines which are parallel to the tooling Axis. By Selecting the point as a support the Bi- Secting lines are created In- between Two parallem Lines. That line is the Main Tooling Axis.
The Bi- Secting Line divides a line into two equal halves. Thus, the perpendicular bisector of a line segment between lines, it implies: It divides two lines which are parallel/ slightly parallel to the Tooling Axis into two equal halves or bisects it.
MATERIAL MODES:
For the Draft Analysis, the material modes are Selected from the Shading Type.
DRAFT ANAYSIS:
For a Class A Surface, The Draft analysis are to be performed in order to meeting te requirement of the draft angle to the required Tooling Axis. For Plastic component the Minimum angle required for the daft to be 3 degrees.
The Direction compass are to be selected and placed it on the Main Tooling Axis line and the comass are been locked using the lock feature in te direction.
In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,
- For 3 degeree - Green Colour Varient (Positive)
- For 0 degeree - Red colour varient.
- For Negative degeree- Blue colour Varient.
By Using the pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 15.102 degeree angle.
The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are imled as Blue colour.
CREATION OF CLASS 'B' SURFACE:
RIB AREAS:
The Rib Areas are selected from the Class A Surface and are extracted by selccting the elemets to be extracted from the class A Surface.
The Extracted surfaces are been Untrimmed using the Untrim Feature and all the elements which are extracted are been Un trimmed.
By using the Extrapolate feature the Untrimmed surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting te features the untrimmed surfaces are been extrapolated to the respectie length provided.
By using the Trim feature the extrapolated surfaces are been trimmed to the sides whic make the Rib as same as Class A Surface.
By using the offset feature the created Rib Area are been offsetted to 2.5 mm from the orign. The same method has been implemented for the creation of the Rib Area 2.
The Rib Areas 2 are selected from the Class A Surface and are extracted by selccting the elemets to be extracted from the class A Surface.
The Extracted surfaces are been Untrimmed using the Untrim Feature and all the elements which are extracted are been Un trimmed.
By using the Extrapolate feature the Untrimmed surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting te features the untrimmed surfaces are been extrapolated to the respective length provided.
By using the Trim feature the extrapolated surfaces are been trimmed to the sides whic make the Rib as same as Class A Surface. By using the offset feature the created Rib Area are been offsetted to 2.5 mm from the orign. The same method has been implemented for the creation of the Rib Area 2.
BASE AREAS:
The Base area 1 are been extracted from the Class A surface and then the surface are been untimmed using the untrim feature. By using the offset feature the created Base Area are been offsetted to 2.5 mm from the orign.
By using the Extrapolate feature the Untrimmed surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting te features the untrimmed surfaces are been extrapolated to the respective length provided.
The Base area 2 are been extracted from the Class A surface and then the surface are been untimmed using the untrim feature. By using the offset feature the created Base Area are been offsetted to 2.5 mm from the orign.
By using the Extrapolate feature the Untrimmed surfaces are been extrapolated by selcting the boundaries and also the extrpolands. The continuty for the extrapolation are selected as curvature and propogation mode are been selected as point continuity. By selecting te features the untrimmed surfaces are been extrapolated to the respective length provided.
FINAL TRIM:
After the extrapolation of Base Surfaces the base surface and Rib areas are been trimmed on both the Rib Surfaces to Make the part as same as the Class A Surface.
The Base Area 2 are been Trimmed with the remaining areas wit the Rib Area wit the Trim Definition and trimming operation has been performed.
EDGE FILLETS:
From the Class A Surface , the fillets are been measured. By using the Intersection from the plane origin the fillet radius are been measured.
By using the Edge Fillet feature the edges are been selected and filleted to 5.5 mm.
- To Make the Inside Fillet = Class A Fillet Radius + Thickness of the Part.
- To Make the Outside Fillet = Class A Fillet Radius - Thickness of the Part.
CREATING CLASS 'C' SURFACE:
To make the Class C Surface, the Boundaried are been Extracted from the Class A Surface. The outer Boundary, Circular Hole 1 and Main Circular Hole Boundaries are been extracted using the Bundary feature.
By using the Sweep surface Creation definition, The respective profile type are been selected and subtype with draft direction are been selected.
In that the Guide curve are selected as the. Boundary in the Class A Surface, and draft direction are selected as Tooling Direction wit the draft angle of 3 degree are perforemed and the creation of Class C Surface.
For Creating the Class C Surface the Two Holes bondaries are been selected and sweep along the tooling axis provided wit the draft angle of 3 degerees.
By using the Join feature the Class A and Class C Surface are Joined Together wit the Merging Distance of 0.001 mm. For Joining with the Class C Surface both the created Holes are been selected and Joined Together.
The Final Trimming Has been performed on the Class B and Joined Class A and C surfaces. Te Trimming as been performed.
CLOSED SURFACE:
By using the close surface definition the part surface are selected to make them into solid part from the part workbench.
DRAFT ANALYSIS:
The Draft Analysis has been performed on the Fianl component created as a closed body usin the part design Closed Surface Feature. For Plastic component the Minimum angle required for the daft to be 3 degrees.
The Direction compass are to be selected and placed it on the Main Tooling Axis line and the comass are been locked using the lock feature in te direction.
In the Display window the clour code varients are been selected, to know the range of the draft in the Class A surface. In the Display Window the colour varient shows,
- For 3 degeree - Green Colour Varient (Positive)
- For 0 degeree - Red colour varient.
- For Negative degeree- Blue colour Varient.
By Using the pointer feature in the Display the draft are been analysed for each individual points. The points perpendicular to the toling axis are displayed as 90 Degeree Direction and the Rib faces are analysed as 15.102 degeree angle.
The drafting are been performed in both the core and cavity side of Class A Surface. The Green colour Implies the draft angle are in the positive region. if The draft angle are been inverted the colour of the surface are imled as Blue colour.
EXPANDED TREE STRUCTURE:
In CATIA the sketches are been defined using the Geometrical sets. By using the profiles like line, circle, hexagon, polygon, arc the 2 -D sketches are been created with reference to the Geometrical sets. According to the selection of plane from the possitioned sketch the 2-D sketch has drawn with the referene plane.
The Publications for the Class A , B and C Surface are Published and also the Min Tooling Axis are been Published using the Publication feature.
3 DIMENSION PART AND ORIENTATIONS:
ISOMETRIC VIEW, FRONT VIEW, SIDE VIEW AND BOTTOM VIEW:
CONCLUSION:
- The Base Bracket Plastic Part Component using the Class 'A' surface are Created.
- The Tooling axis for a class 'A' Surface, which meeting the requirement of the draft angle are analysed and perfrmed.
- The solid model from the surface are created by using the Closed Surface Feature.
- The detailed report which explains the Draft analysis and Tooling Axis cration and colour scale varient are explained.
- The Class A, B and C surfaces are Published using the publication option.
- The expanded Tree Structure for the Geometrical Sets are explored .
- The expanded tree structure for part design are explored.
- The 3D part Model with various orientations are attached.