Week 8 - Challenge 2 - Base Bracket Design

DRAFT ANALYSIS AND PLASTIC COMPONENT MODELLING FOR BASE BRACKET

AIM:

To perform the draft analysis,Tooling axis creation for both the given class-A surface and the final plastic component.

OBJECTIVES:

1. Explain the draft analysis and the tooling axis creation.
2. Creating the tooling axis particularly the Bisecting method.
3. Draft analysis report for both the given class-A surface and the final plastic component.

ABSTRACT:

DRAFT ANALYSIS:The major consideration of draft analysis is whethering sufficient draft angle is provided on the component.Components while designing should be provided with considerable amount of draft angle depending on the manufacturing consideration.For plastic components we provide a draft angle of 3degree.But for automotive sheet metal parts,it will be from 7 degree or more.

TOOLING AXIS CREATION:The direction in which the mold or core and cavity opens is the tooling axis.With the help of toolig axis created along the x-axis and the y-axis,these tooling axes are used for creating by bisecting method.Where the two lines and point will be selected as inputs.

PROCEDURE:

STEP 1: First checking the connectivity of the CLASS-A surface,this can be done by creating boundaries or by using the join command and see how well it is connected.Just ensure there is no surface gap between component or surfaces.This is the first design to check continuity and Quality of the CLASS-A surface.

STEP 2: Analyse visually for the best possible tooling axis for the component.Checking possibilities in all three x,y and z axis directions and finding what are the problem creation parts of the component.The clearance checking along all the axis direction will be done by creating an intersection along an axis on a plane by creating a new axis system with the model and constructing two lines contact with the walls,the line bisecting the two lines and passing through the point wii be tooling axis.A Dummy tooling axis will be directly created using point-direction command after creating boundary for CLASS-A surface and creating intersection with the model.

STEP 3:Publication is used to make easily accessible of the published components.Draft analysis is done after determing the tooling axis,draft analysis is used to check whether the minimum draft angle 3 degree is maintained or not.Compass is used to define the draft direction if the minimum draft 3 degree is provided the whole component changes into green colour.

STEP 4:CLASS-B surface is created by extracting each walls and un-trimming and extraploating the walla to obtain the shape by trimming the excess surfaces and offsetting it to certain distance based on the thickness of the model.The offset surface will be the B-surface.

STEP 5:The surface created using sweep command by sweeping the boundaries of A-surface along the tooling axis to connect from A to B-surface is know as C-surface.Using the B and C surfaces created a closed surface will be formed by trimming the excess surfaces the surfaces will be converted into a solid model using closed surface option.

TREE STRUCTURE:

ISOMETRIC:

FRONT:

TOP:

CONCLUSION: Base bracket plastic components using Class A surface have been successfully created and draft analysis have also been performed for the same.