Week 8 - Challenge 2 - Base Bracket Design

Aim: Creating BASE BRACKET component from given CLASS A-SURFACE.

Description:

A. Steps involved in creating TOOLING AXIS:

1. Create an Axis system at the center of the hole as shown in figure.

2. Create an intersecting curve (using YZ-plane and the Class-A surface of BASE BRACKET).

3. Add a dummy tooling axis.

4. Create lines on the intersecting curve (which are parallel to the dummy tooling axis).

5. Now, create a bisecting line using the lines (parallel to dummy tooling axis) and a point.

This bisecting line will be our Tooling axis for Base Bracket.

6. Publish Tooling axis and Class A surface of Base Bracket for easy selection.

B. Steps involved in creation of Class B-SURFACE:

1. Extract the simple surfaces (which don’t have fillet) and then untrim the extracted surfaces.

2. Extrapolate and trim the surface as per requirement.

3. Offset the trimmed part to a distance of 2.5mm.

4. Performing the above steps on other part of surface we get a surface which is similar to Class A surface without fillets.

5. Now perform the fillets at the edges.

The fillet radius is chosen in such a way that there should be equal thickness at the curved surface.

6. After completion of the fillet the surface we get is CLASS-B SURFACE.

C. Steps involved in creation of C-SURFACE.

1. Extract the OUTER boundary of the class A-surface and two holes separately.

2. Sweep the boundary and holes along the TOOLING AXIS separately.

3. Using ‘Join’ option join all three sweeps (Holes and Outer boundary) and Class A-SURFACE.

4. After Joining the all sweeps and Class A surface, we get Class C-SURFACE.

D. Steps involved in creating PLASTIC COMPONENT:

1. Trim CLASS C-SURFACE with CLASS B-SURFACE.

2. Now, we have a hollow surface of BASE BRACKET which need to be filled with plastic.

3. Change the window to ‘PART DESIGN’ and using ‘CLOSE SURFACE’ turn it to a solid part.

E. Steps involved in DRAFT ANALYSIS ON BASE BRACKET COMPONENT:

1. Select 'Customize view parameters' from the 'View mode' and choose 'Materials'.

2. Select 'Feature Draft Analysis' from the 'Analysis toolbar'.

3. Now, holding the red-dot, which is on the compass (present on Top-right corner of the window) align with the Tooling axis and lock it.

4. Set the Minimum draft angle (3 degree for plastic components) in 'Draft Analysis.1' dialog box.

5. Choose 'BASE BRACKET COMPONENT' as element in 'Draft Analysis' dialog box.

6. After selecting if the color changes to,

a. Green, then the draft of the Part has minimum draft angle of 3 degree.

b. Red, then the draft angle of the part lies between 0-3 degree.

c. Blue, then the draft angle of the part is less than 0 degree.

7. By choosing 'Analyse under running point' from 'Analysis toolbar' we can check the draft angle at any point on the surface just by moving the pin.

F. Steps involved in DRAFT ANALYSIS ON CLASS A-SURFACE OF BASE BRACKET:

1. Select 'Customize view parameters' from the 'View mode' and choose 'Materials'.

2. Select 'Feature Draft Analysis' from the 'Analysis toolbar'.

3. Now, holding the red-dot, which is on the compass (present on Top-right corner of the window) align with the Tooling axis and lock it.

4. Set the Minimum draft angle (3 degree for plastic components) in 'Draft Analysis.1' dialog box.

5. Choose 'Fan Cover' as element in 'Draft Analysis' dialog box.

6. After selecting if the color changes to, a. Green, then the draft of the Part has minimum draft angle of 3 degree.

b.Red, then the draft angle of the part lies between 0-3 degree.

c. Blue, then the draft angle of the part is less than 0 degree.

7. By choosing 'Analyse under running point' from 'Analysis toolbar' we can check the draft angle at any point on the surface just by moving the pin.

G. Screenshots in different views:

1. Isometric View:

2. Front View:

3. Right View:

4. Left View:

5. Top View:

H. Screenshot of CLASS A, B, C-SURFACES and Solid part of Base Bracket.

Conclusion: Solid component is created using Class A, B & C-SURFACES. Draft Analysis on BASE BRACKET component and CLASS A-Surface is done and it satisfies the draft conditions.