Week 8 - Challenge 2 - Base Bracket Design

AIM:

To create the Base Bracket component through the given Class-A surface meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Tooling Axis:
Tooling axis is a direction which defines manufacturability of the part.

Draft Analysis:

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. Most applications require minimum draft angle of around 0.5^o to 1^o, however 3^o draft angles are widely accepted

To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.

Methodology:

Check the Surface

Check the connectivity of the given class A surface with options such as join, Boundary and dis-assemble surface.

Join:

Check the connectivity using join command by selecting the surface as joining elements.

Boundary:

Using Boundary command, check for connectivity of the surface by selecting surface edges

Dis-assemble:

Dis-assemble the element by choosing ‘domain only’ as an option. After checking the connectivity of the given we can delete the curves we got as dis-assemble results and join surface from the geometrical sets.

Create Tooling Axis

As we know tooling axis is the direction that mold pulls apart, the tooling axis should be in a way that component completely clears from the mold and also have a very lesser cost of producing it.

• Create a new geometrical set, name it as TOOLING AXIS.
• Make a point by using circle, sphere and ellipse center as option and hole boundary as the circular reference.
• Create an axis system with that point.
• Intersect with a plane and create a dummy tooling axis.
• Draw lines with two points on the either side of the intersect.
• Draw a bisecting line with the above two lines and rename it as TOOLING AXIS.
• Use Publication from Tools> Publications for tooling axis and class A surface for creating a reference to their geometrical entities.

DRAFT ANALYSIS

• Change the view to ‘material mode’ in customize view option.
• To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.
• Select the mode of operation as quick analysis.
• Selection display option using color scale window.
• Use the compass for selecting the tooling axis in draft direction option and select the surface and lock them.
• If the color scale matches the color of the surface, then the component drafted can be easily removed.

Create Class B Surface

• Extract and extrapolate the surfaces one by one and trim them into a relevant surface

And offset the trim to the required thickness.

• Trim the offsets to create the final surface which is offseted 2.5mm from Class A surface in downward direction.
• The above surface after trimming is class B surface, rename the surface as “Class B Surface” and publish them for easy access.

Create Class C Surface

• Class C surface is the join surface of class A and Class B surfaces.
• Create a boundary for the class A surface along with its holes separately.
• Use Sweep ‘line’ with ‘draft direction’ and guide curve as boundary created earlier and tooling axis as draft direction in downward direction.
• Similarly use sweep for the holes in class A surface.
• Use join command to join the surfaces together
• Trim the class B surface with class C surface.
• Publish them for easy access.

Create Close surface

In part design workbench, create a close surface with the final trimmed surface.

Tree Structure:

Different views of the draft analysis:

Isometric view:

Front view:

Side view:

Top view:

Draft analysis of solid:

Conclusion

Thus, creating the Base Bracket component with given Class-A surface meeting the requirements of the draft angle and at the end perform the Draft analysis on the model done successfully.