Week 8 - Challenge 3 - Coin Holder Design

COIN HOLDER

AIM :

• To Create the Coin Holder Plastic component through the given Class-A surface by maintaining the thickness of the component to be 2.5 mm.
• To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

OBJECTIVES :

• Checking continuity of class A surface.
• Deciding feasible tooling direction & creating tooling axis.
• Performing draft analysis on class A surface.
• Creating class B surface from given class A surface.
• Creating class C surface to join A & B class surface.
• Creating solid feature by using closed surface.
• Performing draft analysis on final plastic component.

PROCEDURE :

We will be recieving a styling class A surface from styling team who deveopes it from a concept sketch to aesthatic class A with styling software for eg:ALIAS.here our work is to get the class A and import it to the design tool to develop Class B & C surfaces.

Firstly,we have to check continuity of given class A surface to ensure class A surface is properly joined or no discontinuity present. This can be done by using join or boundary command in CATIA. By looking visually in below image we see that surface has continuous connected boundary as highlighted by green line. Also this boundary separated into two domains.

• Creating class B surface from given class A surface.

After checking the connectivity we will get into surface workbench to create a solid part having 2.5mm thickness from the given A surface, i.e the B and C surface had to be constructed. The B surface was constructed by extracting all the flat faces on the A surface. Once all the faces were extracted, untrimmed, extrapolated, and were trimmed to give a surface similar to that of the A surface. The surface was then offset by 2.5 mm in the direction where B surface was needed.

untrim so that we can get the original crossectioon

extrapolating the untrimmed surfaces so that we will get the chance to trim it

after trimming we will offset with 2.5mm

below image shows the final trim of class B

• CLASS-C :

In order to construct the C surface, a boundary was created using the Boundary tool and the A surface was used as a reference. A surface was created using the Sweep tool-draft option, and the tooling axis was selected as the draft direction and a draft angle of 3 degrees was given. The A surface was extrapolated by 2 mm using point propagation and all three surfaces were trimmed in order to obtain the final part body.

The next step was to add fillets.In order to this, the fillets on the A surface were extracted and untrimmed and were measured using the Measure Item tool. Once the fillet values were known, it was possible to add them to the B & C surface.

here i have Used the Close Surface feature to make a solid body from the surface.

Creating main tooling axis :

• First extract the base surface & create point on that surface. Insert axis system at that point. Take intersection of class A surface with the XZ plane of axis system. Create two lines along the vertical faces. Create line using bisecting method & passing through that point.
• Perform draft analysis using that line as tooling axis. We observe that few faces of component are not in green. So tilt compass like wise to achieve entire top surface & back surface are in green color except pocket surface. Lock the position of compass.
• Create the line in by choosing direction as compass direction & passing through point on base surface. This is our main tooling axis. After that unlock compass & reset it.

• Performing draft analysis on final plastic component.

Now,draft analysis was carried out on the final body by inserting a Feature draft analysis. It was important that the part body was in customize view with material mode on. The first step was to turn on the compass option and to drag the compass and place it on the tooling direction in the correct orientation. Once it was placed, it has to be locked in that position. Then an 'x' cursor appears as we hover over the body and by clicking on it, the draft analysis is shown. The color code was red - negative, blue 0-3 degrees, and green above 3 degrees. Three degrees were chosen since it is the ideal draft angle for plastic components. The body was green which meant that it was a good design and that it would not cause any problems when the part is being extracted from the mould.

Below i have attached the Screenshots of the Draft analysis report for the final plastic component

fig:Draft analysis using main tooling axis in different views

Note : before submission of model i make sure that i have included all the things are listed below

• Ensure Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set
• Use the Close Surface feature to make a solid body from the surface.
• Publications: Use the publication option and publish the below
  • Tooling Axis
  • Class A, B, and C surface
• Screenshots of the Draft analysis report for both the given Class-A surface and the final plastic component
• Screenshots of the solid model with the proper color code of the draft angle in various orientations (Isometric, Front, Side, and Top View)
• Submission as attachmentCATpart should be submitted as an attachment using the below Browse option.

RESULT :

By the end i have Created the COIN HOLDER component through the given class-A surface by following the operations that are listed below :

• Checking continuity of class A surface.
• Deciding feasible tooling direction & creating tooling axis.
• Performing draft analysis on class A surface.
• Creating class B surface from given class A surface.
• Creating class C surface to join A & B class surface.
• Creating solid feature by using closed surface.
• Performing draft analysis on final plastic component.