Week 8 - Challenge 1 - Base Bracket Design

Objective:

To create a tooling axis for the base bracket model and perform the draft analysis.

Draft analysis feature:

This command is used to detect if the part you drafted will be easy to be removed. This type of analysis is performed based on the colour ranges identifying the zone on the analyzed element where derivation from the draft direction at any point corresponds to the specific values.

The draft is the angle at which the part is tapered to release. As the part is cold, it tends to want to shrink the core side of the mould.

Adding a draft helps to release the part easily.

Tooling axis :

The tooling axis is the axis in which the mould or core cavity opens.

Tooling axis creation :

The connectivity of a class A surface can be determined by creating the boundaries or by using the join command and seeing how it will be connected. This is the first step to check the connectivity of the class A surface.

The clearance check of all the axis directions will be done by creating an intersection along the axis on a plane by creating the new axis system with the model and constructing two lines with the walls. A line bisecting the two lines and passing through the point will be a tooling axis.

Dummy tooling axis:

The dummy tooling axis is directly created by the point to direction line command.

Tooling axis creation by using the bisecting method:

Using the intersection command the lines created along the inclined walls, these lines are creating the tooling axis.

In the line command, the bisecting lines are selected and then both inclined lines are selected along with the point created at the centre of the part.

Then the bisecting line is created. Rename this line as a tooling axis. The tooling axis is created and to visualize more easily add colour to it, convert it into dashed lines.

Publication:

The publication is used to make it easily accessible for publishing the components.

Publish the

1. Tooling axis

2. Class-A surface

3. Class-B surface

4. Class-C surface

Draft analysis :

Draft analysis is done after determining the tooling axis

Draft analysis is used to check if the minimum 3-degree draft is maintained, if a minimum 3 degrees draft is provided the whole part is converted into green colour.

1. Make sure the view is selected by materials.

2. Select the feature Draft Analysis icon.

3. Drag the compass from its position to the tooling axis.

4. select the lock compass.

5. touch on the model if it gets green means the draft is under the 3-degree limit.

6. select the analysis under the running point where the draft is to be measured.

CREATION OF CLOSED BODY:

Creation of Class-B surface:

Class-B surface is the backside surface with respect to the Class-A surface which is an aesthetic surface, Class-B surface carries the engineering features likes ribs, bushes, etc. which are on the backside and not visible to the eyes.

This surface is used to determine the thickness of the component. we can make B-surface in many ways.

Extracting the straight surface and then by using untrim option we have extended surfaces. after that, we use extrapolate command to extend the surface even further. after that, we trim the surface to the desired shape and make offset the shape below the Class-A surface by 2.5 mm

We repeat the same process for the other rib. after extracting the base surface and the upper surface and offsetting it by 2.5mm and then extrapolating the surface that we use the trim option to trim the excess surface and get the desired shape.

After trimming the surface make the fillet to the surface.

Creation of Class-C surface:

Class-B surface is basically a bridge or connector which connects the Class-A surface to the Class-B surface.

We can make the class c surface with the help of the sweep command. For the profile, we use the boundary command to extract the profile of the Class-A surface and for the direction, we use the tooling axis.

For best results, we sweep the holes in the Class-C surface to ensure a perfectly closed surface.

After the Class-C surface, we need to trim the class b surface to the Class-C surface to make the closed surface.

After we have the closed surface we go to the part design workbench and use the closed surface feature to make the surface into a solid body.

Then the final output is a solid body.