Challenge

Week 8 - Challenge 2 - Base Bracket Design

AAbdul Razaq5 Oct 2021

Aim:

To create the base bracket plastic component through the given Class-A surface and at the end performing the draft analysis on the model.

Objectives:

To ensure proper tree structure is followed.
Geometrical sets should have a proper name based on the sketches present inside of it.
All the sketches should be created under the geometrical set.
Use of the close surface to make a solid body from the surface.
To publish the tooling axis,class A, B and C surface.

Procedure:

CLASS-A SURFACE:

First import the class A surface of base bracket model in catia V5.

Check the connectivity of class A surface using boundary option. Ensure that there is no gap between the two surfaces.

TOOLING AXIS:

Now we need to create the tooling axis for the base bracket mode. Visually check which direction is better for creating the tooling axis. First create a dummy tooling axis in Z direction.

Now create the YZ plane at the center point of the hole ( reference point).

Now using the intersect option, select the YZ plane as first element and base bracket ( classA surface) as second element. This will give a 2D sketch of fan cover viewing from Y-direction.

Now create lines through the walls of a bse bracket using point to point op[tion with the help of intersect 1 where I think the tooling might create problems.

Now using these 2 lines create a bisecting line from the reference point in Z direction. This will form a main tooling axis in Z direction.

CLASS_B SURFACE:

Consider the thickness of the component as 2.5mm. Now we need to create a B surface which will be similar to the surface at an offset value of 2.5mm.

First, we are creating the ribs in this operation. To create the ribs, first extract the surfaces of it from class A surface.

Once the surfaces are extracted, unitrim it and then extrapolate it by 10mm by using point propagation. Now trim these surfaces and offset it to 2.5mm.

After creating both the ribs, create the base of the base bracket as mentioned above.

Once all the surfaces are created, trim these surfaces to form a class B surface. Give the appropriate fillets to form B surface.

CLASS-C SURFACE:

To create a class C surface, first extract the boundaries of the class A surfaces as shown in figure below.

Now using the sweep option creates the surface. To perform this operation, go to the toolbar > sweep . Profiletype > Line > Subtype > With Draft direction > Guide curve.1 - (select the extracted boundaries) > draft direction - (select the tooling axis) > angle and length as 3deg and 20 mm respectively and click OK.

For holes extract the boundaries and use the sweep operation to form a surface.

Join the surfaces which are formed by using sweep command to form a class C surface.

TRIM SURFACES:

After creation of Class-A, Cass-B and Class-C surfaces , we need to join Class-A and Class-C surfaces to form a new surface. Then trim the joined surface with Class-B surface to form the final required surface.

Now using the close surface option from part workbench form a solid from surface.

DRAFT ANALYSIS:

To perform Draft Analysis on the base bracket model, first set the view parameters to material Mode.

Then go to the menu bar > select insert > Analysis > Feature Draft Analysis.

To give the draft direction, use the compass and align the Z-axis of it with the final tooling axis for the base bracket model. Once it is properly aligned, lock the draft direction. Select the base bracket and it will show us the current draft angle of the model, set the drafty value to 3deg under the colour scale variant and press OK.

Using the Analysis option, we can perform the draft analysis on the class A surface and final part body of the base bracket.

To publish the tooling axis and Class-A, Class-B and Class-C surfaces first select them and then go to menu bar > tools > publication. This will publish the tooling Axis and Class-A, Class-B, and Class-C surfaces which will be available in the Tree Structure.

TREE STRUCTURE: