Week 8 - Challenge 3 - Coin Holder Design
COIN HOLDER DESIGN:
AIM: To create the Coin Holder Plastic component through the given Class-A surface by creating a tooling axis meeting the requirements of the draft angle and to perform the Draft Analysis on the solid model at the end. The Thickness of the component is to be taken as 2.5mm.
GIVEN CLASS A SURFACE:
The Class A surface is given to us as an input which is checked for any open profiles inside the geometry using the "Boundary" command before starting the construction of Class B and C surfaces. The parts of the Class A surface are differentiated using different colors for us to work on it easily.
EXPANDED TREE STRUCTURE:
REPORT ON DRAFT ANALYSIS AND TOOLING AXIS CREATION:
DRAFT: It is the degree of taper that is incorporated into the side wall and cores of the die cast tool to aid in the removal of a part. Primarily, they function to reduce the friction between the part and the tool as it is ejected. Without draft angles, parts can be stripped, dented, or get stuck in the tool.
The Draft Analysis command enables you to detect if the part you drafted will be easily removed. In the case of plastic injection molded parts it also allows the designer to see if there is enough draft on the part to ensure that it can be correctly grained.
TOOLING AXIS CREATION:
Tooling axis is the direction that the mold pulls apart. It is necessary to create a tooling axis to give draft to the component. Tooling axis is created using the Bisecting Method. For the given Class A surface, the best tooling direction for the component is chosen by considering the tooling of the final product. It is chosen in such a way that the component is cleared with minimum tooling.
BISECTING METHOD:
For a given specific direction, it is found that the given component is clearing the tooling in Y direction. On the Class A, after extracting the base surface a point is created at the geometric centre of the base using the "surface type" in point definition. An axis system is then created with the point as origin.
A dummy tooling axis in the required tooling direction is created for reference while creating the main tooling axis. Then a bisecting line for the two opposite walls is created in YZ plane by intersecting the 3D elements in the positioned sketch.
Similarly another bisecting line for the other two opposite walls is created in XY plane by insection of 3D elements with the plane in the positioned sketch.
After creating both the lines an other line is created using the 'Bisecting Type' in life definition. The inputs given for this bisecting line are the two previous sketches and the center point.
This line thus created is the main Tooling Axis of the component.
It is renamed as Main Tooling axis and is then published for easy accesibility. This is the process for creating a Tooling Axis using Bisecting Method.
DRAFT ANALYSIS ON CLASS-A SURFACE:
Draft Analysis is performed on the Class A Surface after creating the Tooling axis. It is performed to check if the surface clears the tooling.
From the Analysis, it is clear that a minimum draft of 3 degree is maintained for the Class A surface as the colour 'green' indicates that the surface passed the draft check which can be seen from the colour scale table. The second picture shows the Full Draft Analysis of the surface with color scale table.
Thus we can conclude that the Class A Surface clears the minimum required draft for tooling.
FINAL SOLID MODEL:
After trimming and joining all the three Class A, B and C Surfaces, the final solid model is created in the part body using the Close Surface tool in the Part Design workbench. This is the required solid component - Coin Holder.
DRAFT ANALYSIS ON SOLID MODEL:
Draft Analysis is also done on the final Solid Model using the "Draft Analysis" command in the Analysis toolbar to check if the body clears the tooling.
These are the results for the Draft Analysis of solid body in quick and full analysis modes.
DRAFT ANALYSIS ON SOLID MODEL IN VARIOUS ORIENTATIONS:
ISOMETRIC VIEW:
FRONT VIEW:
SIDE VIEW:
TOP VIEW:
