Challenge

Week 8 - Challenge 3 - Coin Holder Design

Tooling axis:

Create a section and check the feasibility of the tooling direction. [SEC VIEW CLASS A].
Taking section along y-z plane, form a mean line with respect to the side walls. Take an intersection on class A and y-z plane on axis system.
The walls are at 0-degree draft. (We should send the design back to the class a design team and request for minimum drafting allowances). In this case we can create a normal line with respect to base.
It is difficult to give thickness to fillets. So, divide the class A surface into different patches in different colours.

Perform extract and untrim for the side walls from inside. Then extrapolate for sufficient distance then trim. Give an offset of 2.5mm outwards
Place all these commands in a geometric set (SIDE WALL)
Create another geometric set “BASE”. Extract the bottom base. Include the side inclined wall as well. Untrim, extrapolate and trim them together.
Create a new geometric set TOP WALL. Extract all the top surface of class A, including the filleted ones, as they are difficult to fillet.
Extrapolate the upper edge and lower edge separately.
Now give fillets for the side wall edges and trim the side wall with the base.
Create a new geometric set called “OUTER FLANGE”. Extract the side profiles and the slanting section and extrapolate the upper edges.
Offset the flange inside and trim it with respect to the side wall. Give it a different colour.
Create an intersect of the obtained class B surface. We need to close the wall and give fillets to the B surface.

We need a surface to close the 2.5mm gap. Change the colour of each intersect and make it differentiable. Here C surface is 90deg to the tooling axis
Create a new geometric set called C SURFACE. Extract the boundary of the outer flange and multi extract the surfaces adjacent to the boundary.
Now go to Draft > with ref. surface (2^nd option). Pick the boundary as guide curve. Pick the surface as ref. surface. Direction is angle = 90deg from the surface. Give the length of 4mm inwards

(The transition areas are acceptable)

Trim the extruding surfaces by extracting the class A, untrimming and offsetting it to 2.5mm and then trimming it with the B surface.

(If the radii <= 2.5mm, then keep the nominal radius of 0.5mm)

Give the necessary fillets. Change the view mode with no borders. Now trim the B surface with C surface and join class A and B+C surface.

Unhide the class A first and the tooling axis. Insert a draft analysis and pick the compass and place it on the tooling axis.
Click on the surface to be analysed.
Similarly do this for class A+B+C.

PLEASE FIND THE FOLLOWING FILES:

-> CATPart.zip (Part Drawing)

-> DRAFT ANALYSIS.zip (Screenshots)

-> Challenge Report.docx (Report)