CHALLENGE REPORT: CHALLENGE REP.docx

Week 8 Challenge 4

TOOLING AXIS

Visually check the component from all the directions on how the component can be cleared through the tooling axis.

Create a point on a surface somewhere in the middle of the component. Create a line along the x axis. Now perform a draft analysis on the class A surface.

B SURFACE

The thickness given to the component is 3mm. As per the thickness give the class A surface an offset of 3mm. This method is called as direct offset method.

After this we will obtain gaps at different positions. Generally, where there are multiple fillets coinciding with each other and where the fillet size is very small.

Note: We should avoid using tools called “fill” and “multi-section surface” while working on class B surface. As the software might wrongly interpret the surface contour and give a wrong output.

To solve these problems:

We have to extract the surfaces which are adjacent to the missing surface. The missing surfaces are generally the fillet element which are unable to be offset to the given offsets.

We try to extrapolate the edges of interest where the fillet is missing. Perform the same operation for the other edge and trim them together to obtain a fresh edge to fillet.

Now to integrate with the main B surface, using extract, choose the option of “complementary mode”. Choose the elements which we had already done the trim operation. This will extract all the other surfaces except the surfaces which we have already worked upon.

Perform the trim operation on the edges adjacent to the worked surfaces and the newly generated surface by extrapolating both of them.

Note: First create a boundary and then extrapolate them to extrapolate long continuous edges with patches.

Give fillets to edges as per the class A requirements. Remember to add 3mm or remove 3mm when giving fillet radius to outer or inner fillet surface respectively.

The B surface must be extrapolated to accommodate the A+C surface. As the surface is divides into various patches, it becomes difficult to extrapolate them individually and then trim them with A+C surface.

It is better to extrapolate them by creating boundary and then extrapolate them. Use the final extrapolate as the final B surface.

C SURFACE:

To create the C surface, we need the class A surface. Unhide the class A surface.

For the creation of class C surface, we use 2 drafting techniques, primarily drafting with reference surface. Only those surfaces which are parallel to the tooling axis, are to be drafted with tooling axis.

Identify the surfaces which are parallel to the tooling axis. Sweep those surfaces using “in draft direction” subtype of sweep. Use sweep subtype of “with reference surface” for those surfaces which are either perpendicular or at an angle with the tooling axis.

Use the same technique of creating boundary and sweeping with reference surface for all other surface. We might obtain gaps where we have 2 adjacent sweeps with sudden change in direction.

Extrapolate those edges, extrapolate them and trim them with each other. In this way we can create class C surface. To create A+C surface, join the C and A surfaces.

FINAL COMPONENT:

To create the final surface (i.e., A+B+C surface), trim the extrapolated B surface with the A+C surface. Check for the gaps and burrs in the surface one final time.

To check it, go to the part workbench and create a closed surface. If it doesn’t throw any error, then the component is complete.

COMPONENT: CATPart.zip

SCREENSHOTS: SCREENSHOTS.zip