Week 8 - Challenge 1 - Base Bracket Design

Aim:

 To  Create a Base bracket plastic component through the given CAT Part file from Class A surface To design a Class B & Class C Surface and final component.

Used via

 Catia V5 software- tools used given below,

• Point through center curve of circle/spear/Arc
• Line in point direction (Z- direction)
• Bisecting line
• Intersection
• Tool Axis
• Draft Analysis in Free from Analysis
• Untrim
• extract boundary
• Extrapolate
• Offset
• Trim
• Join
• Sweep command purticularly with draft direction
• Fill 
• Fillet
• Closed Surface

Tooling Axis:

Taking the Thickness of the component to be 2.5 mm

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

Tooling Direction:

The Tooling Direction is basically the direction that the mold pulls apart. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dyeline or the Tooling Direction. There are different methods to find out the tooling direction. Here we are using bisecting method to find out tooling direction. We can use any method the ultimate aim is to reduce the cost of manufacturing by reducing the complicity in manufacturing the component.

PROCEDURE:

The procedure is divided into two parts first creating the tooling axis then performing the draft analysis.

Creating tooling axis using bisecting method:

• The first thing to do is finding out the possible tooling direction by visually checking the part. Rotate the part in all direction and find out most suitable direction for tooling. Here in this case viewing from Z direction we can clear the face in tooling.
• Then we create a point on the surface of the part, we can create the point anywhere on the surface but usually we take CG point or take a point near to centre. On this point we put a new axis system.
• Then we are finding out the tooling axis in X direction. For that intersect command is used to get the boundary in X direction or XZ plane.
• Extending the drafted face using a point to point line command. Then using bisecting line command bisect both extended line to get tooling axis in X direction.
• Since in Y direction there is no wall to create bisect. We finalise the tooling axis in X direction as main tooling axis.

Publication:

Publication is used to make easily accessible of the published components.

Draft Analysis:

• With draft analysis, you can verify draft angles, examine angle changes within a face, as well as locate parting lines, injection, and ejection surfaces in parts.
• The draft analysis button within CATIA V5 will helps you quickly gather the draft angle on multiple surfaces without the need for tedious manual measurements. Here is a quick rundown of how the icon works when you have a given die direction.

• Performing the draft analysis:

  • Open Feature draft analysis option from Insert > Analysis > Feature draft analysis.
  • A new window pops up by default it will be in quick analysis mode. Change the range to 2.9deg.
  • Next you have to position the compass on the tooling axis by dragging the compass from top right corner of the working area. The W axis of the compass should be inline with the axis.
  • Then you have to define the compass by click on compass icon on the draft analysis window. Then lock the positon of the compass by clicking the lock icon.
  • After that select the surface and the whole surface will shows a color range. For a good draft make the surface fully green.
  • The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
  • The draft angle of plastic part prevents the plastic parts from sticking to the mold, which causes the plastic part to deform. The draft angle is generally 3°-5°.
  • Draft angle dimensioning:

    1. Typically, one to three degrees draft is recommended.
    2. For untextured surfaces, generally a minimum of 0.5 degree draft per side is recommended.
    3. For textured sidewalls use an additional 0.4 degree draft per 0.1mm depth of texture.

     
     

• DRAWING:

  class A surface:

  

  Tooling Axis:

  

  Free from Analysis:

  

  Class B Surface:

  

  Class A+C Surface:

  

  Final component:(Class A+B+C Surface)

  

  Final component draft analysis:

  

  

  Closed surface:

  

  CONCLUSION:-

     In this project designed the base bracket and made ready for manufacturing by allowing a proper draft according to the requirement.