Week 8 - Challenge 3 - Coin Holder Design

COIN HOLDER DESIGN

AIM:

To create the coin holder plastic component through the given Class A surface. Take the thickness of the component to be 2.5mm.

DESCRIPTION:

CLASS-A SURFACE: the class-A surface is used in the automotive design industry. it the describes the final production surface data for the aesthetic parts of the car.

CLASS-B SURFACE: The Class B finish is a quality finish with only minimal imperfections.

CLASS-C SURFACE: The interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic finish.

DRAFTING ANALYSIS:

• Draft analysis is performed on the components where the ejection of materials happens after the material is made inside the tools.
• In the case of automotive sheet design manufacturing, the blank sheet after turning into automotive panels like Hood, Fender, Roof, Side Doors, Back Doors etc. need to be removed from Panel Dies.
• If a considerable amount of draft angle is not provided, the removal of components from the tool will be difficult.
• It’s the same in the case of mold(plastic component) after getting filled inside the core and cavity, it needs to get ejected easily with the help of ejectors.

TOOLING AXIS:

• 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 bin. Same is done with this component. A line normal to base surface is created and considered as tooling axis.

CLASS A SURFACE:

• In automotive design application Class A surfaces are created on all visible exterior surfaces (ex; body panels, bumper, grill, lights etc.) and all visible surfaces of see-touch in interior (ex: Dashboard, seats, door pads etc.)
• class A surface should be given and we dont make any dimension changes.

CLASS A DRAFT ANALYSIS:

CLASS A TOOLING DIRECTION:

CLASS B SURFACE:

• As usual B surface is created using standard procedure by extract, un trim, extrapolate and offset commands.
• B surface of this coin holder is divided as base, side walls, top wall and outer surface. B surfaces of all these sub parts are created and trimmed together to join as single surface.
• The offset distance is kept 2.5mm as component thickness is 2.5mm

CLASS B EXTRACT & UNTRIM:

CLASS B FINAL:

\

CLASS C SURFACE:

• Class C surface for this component is created using boundary command.
• To create C surface boundary of Class A surface and use smooth curves.
• Then sweep with reference surface commands is used and surface is created at 90 degrees and join class a and class c.

CLASS A & B & & C:

FINAL DRAFT ANALYSIS:

SOLID PART:

MATERIAL USED IN COIN HOLDER:

ACRYLONITRILE BUTADIENE STYRENE(ABS):

High Rigidity:

• ABS has high rigidity and impact resistance. Even in low-temperature conditions or over long periods, ABS plastics will retain these characteristics.
• Its tensile strength is around 35-44 Mpa and because of its plastic yield at high strain rates, the impact failure of ABS is ductile rather than brittle.
• It is used in Instrument-Panel, Door-trims,Coin holder etc. As it has good impact resistance, it is used in creating bumpers as well.

Excellent Insulation:

• It has very good insulating properties, both acoustic and thermal.

Highly Weldable:

• It is a good weldable material as it is an amorphous material
• It is usually measured in terms of stiffness or modulus.

High Dimensional Stability:

• It remains mechanically strong over time.

Good Surface Characteristics:

• High Surface brightness and excellent surface finish. ABS is an ideal material whenever superlative surface quality, color fastness, and luster are required. ABS is a two-phase polymer blend.
• A continuous phase of ‘Styrene-Acrylonitrile’ co-polymer(SAN) gives the material rigidity. Hardness and heat resistance. The toughness of ABS is the result of microscopically fine polybutadiene rubber particles uniformly distributed in the SAN matrix.
• Hence, ABS is also used in Wheel-covers, IP substrate, etc

Good Abrasion & Strain Resistance

TREE STRUCTURE:

CONCLUSION:

• To use class-A surface and create Tooling axis, Draft analysis were performed.
• The solid component was created from the surface model.
• The class A surface provided in the challenge has no hole and cat part cannot open.