Challenge

Week 8 - Challenge 3 - Coin Holder Design

SSaravanakumar M K18 Jul 2022

Creating the Switch Bezel Plastic component using Catia:

Class A Surface:

The Class A surface is gives is shown in below image:

Procedure:

Step 1 : Connectivity of the Class A Surface

Check the connectivity of the Class A Surface that is to check that there is no gap between the components using the Join command or by visual inspection or also by using the Boundary Command.

Step 2 : Tooling Axis

The Tooling Axis is created using Bisecting Line Method.

Bisecting Line Method:

In Bisecting Line method is that the possiblities or clearance is checked along the direction using the intersection of surfaces along the axis on the plane of the Class A surface and the two lines is created on the intersections walls that is along the inclined walls of the intersections. Then the line is created by using bisecting line option in line command using the two lines and the point created and that line is Tooling axis.

For Creating tooling axis we create the point. The image of point is shown below

Then the intersection is created using ZX plane using Axis System and point as reference. The below image shows the intersection

As the walls are 90 dgree to the base, wedirectly created a line usig base and point as reference and the line is our tooling axis. The image below shows the Tooling Axis.

Step 3 : Draft Analysis

Draft anlaysis is done based on the tooling axis. Draft analysis is used to check the Class A is maintained with minimum draft angle of 3 degree.
The Compass is used define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the surface. The image shows that draft analysis of the Class A surface with color scale variant.

Step 4 : Creating Class B Surface

First we extracted the Side walls using Extract command.
Then we untrim the extracted surface using Untrim command.
Then the untrimed surface length is increased by using the Extrapolate command.
Then those extrapolated sutrfaces are offseted using Offset command with thickness 2.5 mm which is given.
Then the offseted surface are trimed using Trim command and thus obtained our Side walls.
Similarly we created Base, Top walls and Outer Flange using above mentioned steps.
Then we trimmed those surfaces using Trim option and thus we obtained our Class B Surface.

Step 5 : Creating Class C Surface

The Class C surface is the connection between Class A and Class B surface.
The Multi Extract command is used to get the boundaries and also surfaces of the Class A surface.
These Boundary and surface is swept using Sweep command with reference surface option and angle is mentioned as 90 dgree and length is 4 mm, we use Sweep command with reference surface option because the intersection is perpendicular with the Tooling Axis.
Thus Class C Surface is obtained. The image shown below is Class C surface

Step 6 : Final trim to obtain Coin Holder Plastic component

The last step is triming the Class c surface with the Class B surface.
Then Trimed surface is joined with Class A surface.
Then the obtained surface is converted into solid using Close Surface and thus the final Base Bracket Plastic Component is obtained. The image is shown below is Coin Holder Plastic component

Screenshots of the solid model:

Isometric:

Front View:

Back View:

Side View:

Top View:

Draft Analysis of the Solid:

Draft analysis is used to check the solid component is maintained with minimum draft angle of 3 degree.
The Compass is used to define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the solid. The image shows that draft analysis of the solid with color scale variant.

Screenshots of the solid model with the proper color code of the draft angle in various orientations: