Week 8 - Challenge 2 - Base Bracket Design

Aim: To create a Base Bracket Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component.

Objectives:

• Creation of tooling Axis.
• Creation of Class B and Class C surface.
• Creating a solid part out of surface modelling.
• Draft Analysis of Class A surface and final plastic component.

Tool Used: CATIA V5

Introduction: In this project we are designing a base bracket using given class A surface. The approach includes creations of Class 8 surface keping 3 mm thickness in mind for the complete component. The designs also included Class C creation from the given parent surface.

Constraints:

• NO CHANGES IN CLASS A ARE ALLOWED PART THICKNESS CANT DEVIATE BY MORE THAN 30%
• ALL DESIGN RULES SHOULD BE STRICTLY FOLLOWED
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID
• ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS

CLASS A: Following surface is given as the input for the component creation.

To continue with the design process first we need to find out the tooling axis for the surface and check for all the drafts using Draft Analysis tool of CATIA.

Draft analysis for surface A:

• Go to inserts analysis feature draft analysis.
• Align the tooling axis with the compass.
• Click on the surface and see that the surface is within the permissible limit of the draft values.
• The surface should be green and in the column proper value (3deg) should be insert.

Creating of tooling axis:

• Create an intersection of class A surface with ZX plane and from the intersection create the tooling axis as shown below.

• Create a bisecting line using the lines shown above.

• Here line showed in dotted yellow is our tooling axis.

Creation of Class B:

• Now for Class 8 creation, we have extracted surface from Class A and untrimmed them to obtain the original parent surface.
• These surfaces are then offset to the required thickness.
• After offsetting all the surfaces are trimmed into the required shape.
• Required fillets are given to the surfaces.

Creation of Class C:

• For creating this surface we have extracted the boundry of Class Ausing multi-extract and then converted to smooths curve.

• Now this smooth curve is swept along the draft direction with a 3deg draft.

Final Trims:

Class A-Class C:

• To make sure that there is not any open boundry between class A and class C we have used jein option to created the single body. This is done to make sure that the parting fine doesn't Be between the these two surfaces.

Class A+Class B+Class C:

• For this we have trimmed the above shown surface with class B using trim feature.

Different views:

Draft analysis on the final component:

For this draft analysis,main tooling axis is taken draft reference.

Following results were obtained.

Closed Surface:

Tree Structure: