Week 8 - Challenge 2 - Base Bracket Design

AIM - To create the Base Bracket Plastic component through the given Class-A surface and to perform the draft analysis on the model.

PROCEDURE - Here Class A Surface which is given to me is shown below:

Now from the above-shown fig. I have to create the solid component creating the CLASS B and CLASS C surface. so first I will create the tooling axis.

The Tree structure of the complete model is shown below:

Tooling axis - The tooling axis is defined as the direction in which the mold opens or core and cavity opens and closes. The selection of the correct tooling axis is important to ensure the component is taken out perfectly and also the cost of the component should be less.

I will start by insering a geometrical set and naming it as a tooling axis. For creating the tooling axis I will analyze the model and first create the dummy tooling axis. So on analyzing the model I found out that the z-axis will be perfect for creating the tooling axis. Because along the Z direction, only the whole component is visible.

First, I will create a point on the bigger hole and from that point, I will create one line along z-direction that will be my dummy tooling axis. The dummy tooling axis is shown below:

next, I will an axis system from the point which I have created in that hole. Then I will create an intersection of the surfaces along x and y-direction. Because the tool should be clear in both x and y-direction. Here in the x-direction, I won't be creating any intersection because in the x-direction for the Class A given it won't cause any problem. But in the y-direction, I will create the intersection between the yz plane of the axis system and the glass surface. The intersection parameters are shown below:

Then I will create lines for the surfaces that would cause problems during the ejection of the part from the mold. So basically I will extent those lines which are not perpendicular to the dummy tooling axis that I have created. Neglecting those parts which have fillets. The lines are shown below:

After doing this I will create one line bisecting the two lines that I have created and I will name it as my tooling axis. so my bisecting the lines I will make sure that the ejection should be perfect without any problems. The tooling axis parameters are shown below:

So now i have created the tooling axis and it is shown below:

Then after creating the tooling axis I will perform the draft analysis on the class A surface.

Draft analysis - Draft analysis is a technique to analyze whether the component created is manufacturable or not based on the draft conditions applied. So here I will provide the direction in which the component should be ejected to get the easy removal. My dirction will be the tooling axis that I have created.

The minimum draft value for the Automotive plastic component is 3 degrees and those for the texture faces 7 degrees od draft is suitable. The draft is provided to the component for easy removal from the mold in the case of a plastic component.

So here i will change the customize view parameters and will select the material mode.

Then i will go insert and select the analysis and in analysis, i will select the feature draft analysis. The feature draft analysis block is shown below:

In the above fig. under the display, section selects the color scale and turn on the light effect for proper visualization. then under the direction section, I will click on the compass and will drag the compass from vehicle zero to my tooling axis. and then I will click on the lock feature and will select the class a surface. The result is shown below:

The color scale is shown below:

In the above fig. The Green color shows that the draft provided is more than 3 degrees

The Red color shows that the draft provided is between 0 and 3 degrees

The Blue color shows that the draft provided is negative.

As I have already mentioned that the minimum draft for plastic components should be 3 degrees and in the class A given to me it satisfies the condition so now I can work forward and now I create the Class B and C surfaces.

For creating the class B surface again I will insert a geometrical set that will have all the constructional elements.

CLASS B SURFACE - It is a surface that gives thickness from class A surface. All the supporting features of the component will be formed on the B surface only. so we can say that Class B is an engineering surface and Class A is an aesthetic surface.

I will start by creating the side ribs from the class A surface. For that, I will extract the surfaces of the ribs. The extracted surfaces are shown below I have given color to them as well.

After doing the extraction I will untrim the extracted surfaces. The untrim is shown below:

And then to 1o mm, I will extrapolate the surfaces. The extrapolate parameters are shown below: I will extrapolate the three surfaces that I have untrimmed.

Then i will trim the surface i have extrapolated to get the required shape of the first rib. The trim is shown below:

Then I will offset it to 2.5 mm because 2.5 mm is the thickness that I want for my component. The offset is shown below:

Now the same thing I will do for the other Rib.

The extract of rib 2 is shown below:

Then I will untrim the extracted surfaces. The untrim is shown below:

Then again I will extrapolate it to 10 mm. The extrapolated surface is shown below:

Then I will do the trim for the extrapolated surfaces to get the required shape of the second rib. After the trim I will offset the trim to 2.5mm which is my thickness value. The trim and offset are shown below:

After creating both the ribs I will create the base surface following the same procedures as i did it for the ribs. So for the base surface, i will extract both the base surfaces from the class A surface the first surface which is a slant surface and the second is the lower base which is the flatter one. The Extracted surface is shown below:

Then I will untrim the extracted surfaces and extrapolate them to 10 mm. The untrim and extrapolated surfaces are shown below:

Then I will offset the extrapolated surfaces. The offset is shown below:

Then I will do the final trim. First, I will trim the ribs and slant surface then I will trim the result of the first trim with the base surface. The Final trim is shown below:

After doing the trim I will provide the fillets to the edges. The fillet parameters are shown below:

After providing the fillets the output surface that I got was my CLASS B surface. The CLASS B surface is shown below:

After creating the Class B surface I will create the class C surface.

CLASS C SURFACE - Class C surface is defined as the surface which connects the CLASS A and CLASS B SURFACE along the tooling direction. The tooling direction here will my tooling axis.

So for creating the Class C surface again I will start by inserting a geometrical set. Then I will create the boundary of the class A surface. The Boundary is shown below:

Then i will create the sweep. The sweep will be of a line type profile with subtype as draft direction. The draft angle will be 3 degrees. The sweep parameters are shown below:

Now in the components, there are two holes as well so for those holes I will do the same thing. That is I will create the boundary and sweep

the boundary and sweep is shown below:

Then finally i will join the sweeps creates with the Class A surface. The join parameters are shown below:

Then I will do the final surface trim. The trim will be of class B surface and the join of class A and class B surface. The trim is shown below:

After doing this i will go to part design and select the close surface feature to create the solid part from the surface I created. The solid base bracket is shown below:

Then I will perform the draft analysis again but this time on the whole part body. So for draft analysis, I will follow the same process as I did for the draft analysis of Class A surface That is first change the view parameters to material mode and then go to insert then analysis and under that select draft analysis.

Then I will drag the compass to my tooling axis making sure that the direction is correct. The result of the draft analysis is shown below:

The color scale is shown below:

In the above fig. The Green color shows that the draft provided is more than 3 degrees

The Red color shows that the draft provided is between 0 and 3 degrees

The Blue color shows that the draft provided is negative.

As I have already mentioned that the minimum draft for plastic components should be 3 degrees and class A given to me it satisfies the condition. So now I can say that my component which is the base bracket is manufacturable.

RESULT - The Base bracket plastic component is created and the draft analysis is formed on the component and is shown below:

The Class A and Class C surface is provided with a draft of above 3 degrees and Class B has a negative draft of 3 degrees.

CONCLUSION - This concludes the creation of the Base Bracket Plastic component through the given Class-A surface.