Week 8 - Challenge 3 - Coin Holder Design

• AIM:- Given Class A input surface, complete the thickened Coin Holder part and perform draft analysis on the completed part.
• DESIGN CONSIDERATION:-

Class – A surface should be aesthetically smooth and good.

Class – B surface should have all the supporting features like ribs.

The parting Line should coincide with the B surface since flashing couldn’t affect the aesthetic of Class – A.

Class – C surface should also pass the draft analysis.

• TOOLING AXIS DIRECTION:-

Generally tooling axis is created using bisecting line method. But in the components where it has a bin, then the tooling axis is considered as a line normal to the base surface of the bin. The same is done with this component. A line normal to the base surface is created and considered as a tooling axis.

• BISECTING METHOD:-

1. Identify on which plane we have to do more operations and create the plane or axis on the component area and define it on the dummy tooling axis direction.
2. Intersect the class A surface with that plane then we will get an intersection sketch. Look for the profile (inclined line) which will create a problem and extract it then extend it by using the line command.
3. Then create a bisecting line with reference to the lines we have extended and this will be our main tooling axis.
4. In this case, we have created a tooling axis along with the Y direction with reference to the base surface.

• CLASS-B SURFACE:-

1. In the case of Class A, the surface below is called the core and the surface above is called the cavity.
2. Class A is an aesthetics surface and class B is an engineering surface.

3. B surface should be inside the class A surface.

4. B surface can be divided into four surfaces the side walls, top walls, outer flange, and the base surface, and later trim altogether.

5. the First step is to create the side wall surfaces by extracting the required surface from Class A and untrimmed it thus we will get a single surface which will be extrapolated to get the required size and finally offset it to the inner side of class A as per the thickness of the material and trim them together and apply the required fillet by measuring the values from class A.

6. Base surface of the component is then extracted, untrimmed, extrapolated, offset, and trimmed.

7. The top walls can be directly extrapolated from the extracted surfaces and offset it for the required size of the material.

8. Then join the base, side wall, and top wall by trim operations.

9. As the Outer flange is surface complex it can be divided into two parts and extracted then go for extrapolation, offset, split and join operations, and finally check for the connectivity by intersecting method.

10. Now all four geometries are trimmed together to get the B surface.

11. Fillet is applied to the required surfaces by measuring the fillet value from the class A surface.

• CLASS-C SURFACE:-

1. C surface has been created from the boundary lines of class A surface and by extracting the supporting surfaces then sweeping the boundary lines with reference to the extracted surfaces.
2. In order to get the C surface first, we have to create a boundary line of class A surface or by using multiple extrapolated commands and check for its continuity of it.
3. Create a sweep with reference to the curve and the reference surface with a 90-degree angle and give the inside direction Check for the continuity of the surfaces if there is any gap go for extrapolated and trim all together now we will get the class C surface.
4. Then join the class A surface and C surfaces together by joining command then check it for connectivity of the surfaces if it is ok then finally trimmed it with B surface we will get the final component again and check whether the final body is closed by using boundary command.
5. A closed solid body is created by using the close surface on the part workbench by selecting the final Trimmed component and doing the draft analysis for the same.

• DRAFT ANALYSIS:-

No parts can be ejected from the tool if it is having a straight 90-degree profile from its base surface. A small draft angle is provided to each and every area of the component in order to get easy removal of the component from the tool. The draft analysis technique is used to analyze whether our part model created in cad is manufacturable based on the draft condition applied. Here the part should get easily removed from the panel dies (in case of Sheet metal part) or Mold (in case of plastic). Here we are providing a direction in which components should eject in order to get easy removal of components from the tool. In other words, it also lets us know whether the model is having a draft angle and how much is the draft angle from the tool direction.

• The draft allows for the component to release from the mold, most parts or applications require a minimum of 0.5 to 1-degree draft angle and a 3-degree draft angle is widely used as per the norm.
• Change the material mode to customize mode before moving to the draft analysis.
• Insert –analysis-feature draft analysis
• Defining the draft direction Select draft analysis from the toolbar and click on the compass symbol and pull the compass from the right side top corner of the workbench and place it on the component where want to do the draft analysis. ‘W’ of the compass and tooling axis should be aligned on the same line.
• Once the compass is aligned with the tooling axis click on the lock symbol and drag on the surface we will get a wrong mark then select that point a table will appear it shows the draft value on the table we can adjust the draft value and analysis it for all the edges and surfaces.
• By clicking on the surface and using the flipping tool we can assign the Flipping direction and the color of the surface change as per the flipping direction.
• Analysis under running point and move the mouse on the surface and will show the details of the surface deg direct at each and every point of the surface.

• ALL SIDE VIEWS:-

• TREE STRUCTURE:-