Week 8 - Challenge 4 - Coin Holder Design

OBJECTIVE :

• To design coin holder as per automotive OEM Standard.
• Create B Class and C Class and tooling axis.
• Convert close lose the surface into the solid body and provide the thickness of 2.5mm.
• Performing draft analysis to verify the creation of the Tooling axis and C Class surface.

SOFTWARE:

• CATIA V5 (Generative Shape Design)

INTRODUCTION:

CLASS-A SURFACE:

A surface made by the designer is given as an input to the plastic modeller to work on. It is an aesthetic surface and the outermost surface.

CLASS-B SURFACE:

A surface after a certain thickness from the class-A surface is a class-B surface. This is the surface that contains engineering aspects of a model.

CLASS-C SURFACE:

A surface that joins class-A and class-B surfaces is a class-C surface.

METHODOLOGY:

In this model, we have focused on the following things:

1. Tooling axis
2. Draft analysis
3. Class-B surface
4. Class-C surface
5. Making a solid model from the surface.

CLASS-A surface:
Surface gave by the Styling team to Design Engineer.

1. Check the given class A surface for any surface openings neglecting the feature opening using the boundary feature. Fix the openings using the Join feature if needed.
2. Create a tooling axis exactly at the centre of the pocket feature, by extracting the base surface of the pocket, creating a centre point on the extracted surface and create a line from the point facing the Z direction at 90 degrees from the base as shown below.

Procedure for creating Tooling Axis

1. Intersect the model with the plane perpendicular or to an axis system.
2. Extend the lines which are perpendicular to the plane.
3. Again intersect the model with another plane and extend the lines perpendicular to it.
4. Create a bisecting line by bisecting option in Line definition.
5. Rename it as Tooling Axis.

Procedure for creating B Class surface

Side Walls:

• Extract the side walls with no propagation in the extract option.
• Untrim them.
• Extrapolate the walls with point continuity of distance 20mm.
• Trim the walls to get the required shape.
• Offset those trimmed walls with thickness value.

Top & Bottom Surfaces:

• Extract the surfaces separately and untrim them.
• Extrapolate the surfaces with required distances.
• Offset them with thickness value.
• Trim them for the required shape.
• Measure the fillets, calculate it and create fillets.

Procedure for creating Class C Surface:

• Get the boundary lines of Class A surface separately.
• Smooth the curves with a smooth option as boundary lines have a lot of vertices.
• Sweep the curves with the tooling axis as a direction in the Sweep option.
• As both lines do not intersect, extrapolate them with a certain distance.
• Trim the surfaces.

Procedure for creating Closed Body

• Join the Class A and Class C surfaces.
• Trim those joined surfaces with Class B surfaces.
• Go to Part Design and insert a Body.
• Create a closed surface.

Procedure for creating Draft Analysis:

• Go to the Insert menu and select the Analysis option.
• Select Feature Draft Analysis.
• Select the Material option and select the surface.
• Drag the compass and place it on the tooling axis.
• Make sure that the top surface is in green colour as the draft angle should not exceed 3deg.
• Click on Okay after confirming the model.

ISOMETRIC VIEW

TREE STRUCTURE