Week 8 - Challenge 4 - Coin Holder Design

REPORT

DRAFT ANALYSIS ON CENTER CONSOLE COIN HOLDER

Aim: To create a center console coin holder design using the given class-A surface and perform the draft analysis using the tooling direction to ensure easy removal of the part from the mold.

Objective:

• Ensure Proper Tree Structure
• Thickness of the component to be 5 mm
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set
• Use the Close Surface feature to make a solid body from the surface.
• Publications: Use the publication option and publish the below
• Tooling Axis
• Class A, B, and C surface

PROCEDURE: -

• Basic checks
• Check the connectivity of the class-A surface i.e. ensuring there are no surface gaps between the surfaces.
• This can be done either visually or manually by creating boundary of the component.
• The best way to know the connectivity and quality of the component is by checking how many domain boundaries have been generated using disassemble command.
• We can see in the below image, we are having two domain boundaries created one for the hole/pocket and another for the exterior boundary.
• The next step is to perform the draft analysis and for that we need the tooling axis

1. TOOLING AXIS:

• Tooling axis is a line in which the core and cavity opens and the component is ejected.
• Visually check which would be the best direction for the tooling axis.
• Usually when there is hole or a bin in the component we will be considering those two as the primary area for creating the tooling axis.
• Initially take(extract) the base flat surface present on the component and create line normal to the surface by creating a center point or an axis system on the base surface.

• When we observe the component by drawing a intersection line in the middle, we found that the component has no draft i.e. the walls of the component are straight, we can also confirm it by using measuring tool

• Hence in this type of component where the walls are flat or at 90 degrees, we can simply draw a tooling axis which is normal to surface.
• Therefore, we will create normal line to the base surface and consider it as main tooling direction.
• Perform the draft analysis of the given class-A surface to ensure the tooling direction is clearing the past and is easily removable from the mold with the help of color scale.

1. DRAFT ANALYSIS: enables you to detect if the part you drafted will be easily removed.

• The visualization mode should be set to Shading with Edges in the View > Render Style command before performing draft analysis.
• Go to insert<analysis
• The Draft Analysis dialog box is displayed. It gives information on the display (color scale), the draft direction and the direction values and identifying the maximum and minimum values for the analysis is displayed too.
• We will be using the default mode i.e. the quick mode as it simplifies the analysis in that .it displays only three color ranges.
• The maximum and minimum values for the analysis should be adjusted to 0 and 3 respectively as per the automotive industry as displayed below in the color range box.
• Drag the compass by holding left mouse button on the red dot of the compass and place it on the main tooling axis randomly.
• Click the Compass icon to define the new current draft direction by aligning the compass exactly along the main tooling axis.
• Click the Locked direction icon , for locking the direction of the tooling axis.
• After locking the direction single click on any random area on the component or surface.
• The part will be shown colored either or mixture of the three colors (green, red, blue) on it.
• Three bands of color on the part in the below example will indicate
• Green: the area has draft angle more than 3 degrees
• Blue: the area has the draft angle between 0 to 3 degrees.
• Red: the area has draft angle below 0 degrees (negative draft angle)
• In the above door arm rest example, the green area indicates that the part has draft angle more than 3 degrees and easily clearing the mold, while blue area has the draft angle between 0 to 3 degrees
• Similarly repeat the draft analysis on the close surface (solid model).

CLASS-B SURFACE

• Divide the surfaces of class-A surface into simple patches by giving different colors as shown in below image accordingly divide the geometrical sets in the Class-B surface to simplify the steps.
• Name the sub-geometrical sets in Class-B surface accordingly.
• The offset value for creating Class-B surfaces is provided i.e. 2.5mm.
• Extract >Untrim>extrapolate >offset the patches as divided.
• Use the various surface commands such as boundary, trim, split etc. available in the generative shape design and create the Class-B surface accordingly.

SIDE WALL

BASE

TOP WALL

OUTER FLANGE

INNER RIB

B-SURFACE TRIMS

CLASS-C SURFACE

• Create an exterior boundary or parting line for class-A surface and also for the hole/pocket.
• Using the available commands like sweep create the class-C surface at an angle 90 degree to the tooling axis.
• Join the class-A surface and Class-C surface after by ensuring no gaps between them.
• Trim the class-B surface after performing the above step and create a close surface.
• Cross check the final closed surface is completely closed ort not by using boundary command.

CLOSE SURFACE

• Go to part workbench and create a solid body out of the close surface.
• And perform the draft analysis again.

DRAFT ANALYSIS ON FINAL SOLID COMPONENT

TREE STRUCTURE