Week 8 - Challenge 4 - Coin Holder Design

Week 8 - Challenge 4 - Coin Holder Design

Aim:

• To create proper tooling axis considering the required draft angle of a component.
• To perform draft analysis on the given Class A Surface.
• To create Class B and Class C Surface and make a solid body.
• To perform draft analysis on the final component

Given Input:

Tooling Axis creation:

1. The first step is to check the class A surface using either the join command to check for any connexity errors or the boundary command to check if there are any discontinuities.
2. Then the model is visually inspected to determine the best posssible tooling axis and a dummy tooling axis is created.
3. In this case a point is created at the center of the base surface of the pocket and an axis system is created at this point
4. Intersections are created between this class A surface and XY and YZ Plane of the newly createed axis system.
   
   
   
   
5. Tapered surfaces in this intesect is examined. In this case draft is not provided to any of the size walls. All the walls that are parallel to the tooling axis need to have draft. So we need to request to styling team to modify the Class A Surface with draft.
   
   
6. For now a line is created normal to the base surface of the coin holder pocket. This line is the Tooling Axis.

B Surface Creation

1. The surfaces present in the Class A Input need to be need to offset excluding the fillets. The offset value should be the thickness of the part.
2. All the Primary Surfaces are extracted and untrimmed.
3. Then these untrimmed surfaces are extrapolated on all sides and offset to 2.5mm.
   
   
   
   
4. These offset surfaces are now trimmed to each other.
   
   
5. Finally fillets are added to this B Surface. The fillet value for the B surface is determined by measuring the fillet value of the Class A surface and then calculating the offset fillet from it by adding or subtracting (based on whether the fillet is external or internal) the part thickness to the fillet value.
   
   
   
   
6. The B surface is given a different colour to distinctively identify it.

C Surface Creation

1. C Surface is the connecting surface between the Class A and B Surfaces.
2. First step is to create a boundary around the Class A surface and the Hole.
   
   
   
   
3. Now using the Sweep command and having the Profile Type as Line and the Subtype as With reference surface create a sweep using the boundary as the Guide Curve 1 and the extracted Class A Surface as the reference surface with an angle of 90 degrees and the arrow pointing inwards.
   
   
   
   
4. Using this same procedure C Surface is created for the hole.
5. The C Surface is given a distinct colour to make is easy to identify.

ABC Join:

1. Class A surface and C Surface are joined using the Join command.
   
   
2. The A and C join surface is now trimmed to the B Surface
   
   

Creating a Solid Body

The ABC join surface is made into a solid body by using the Close Surface command. This close surface is created in the Part Body.

Draft analysis on the final body

Draft analysis on the final body shows that the Class A surface (Green) will be formed by the Cavity while the B and C surface (Blue) will be formed by the core.