Week 8 - Challenge 4 - Coin Holder Design

REPORT-

Input Given to us is a Center Console Class – A surface.

Output expected to create a Coin Holder Plastic component with required thickness. Tooling Axis should be created along with the draft analysis of the surface and the Plastic component.

Procedure for Tooling Axis Creation-

1. Check the basic checks before starting. Check connectivity of Class – A using Join or boundary operation and ensure that there are no gaps in the Class-A. Perform initial checks to check for incomplete patches.
2. Look at the component and check the sides for the best fit as per the axis according to the XYZ of the vehicle that are most suitable as tooling direction, imagining them considering tool movement and side core minimization requirement.
3. Create a geometric set for Tooling axis creation. We create a dummy tooling axis to help us imagine the XYZ of the vehicle using a point or a plane, one that is derived from a hole or with reference to component itself.
4. Create 2 intercepts using axis System planes XY and YZ, i,e., along x and z directions. Make the position sketches accordingly making sure that all faces are clearing dummy Tooling. Use the Bisection method to create Tooling axis along x and z direction using faces that you think that might create problems.
5. We can Create a dummy tooling for our reference while Working on Bisection Method. Use the dummy Tooling axis to check whether all the Faces made using intercept clear the dummy axis.

Faces Perpendicular (90 deg) with Dummy tooling- definitely clear

Some Face Visually they look they will Clear but we have to cross check with the tooling analysis.

The Problem comes with Parallel Face (at zero deg) or negative face (less then zero).We have to check for draft analysis and check whether they clear the tooling axis or not. We have to ensure that they are Positive.

6. Bisecting method on ZY plane-

Using the axis system on the ZY plane, Identify the faces that may create problems. Here there is two face at 90 deg with the base. Tooling Axis for z might be considered as the Perpendicular line with the base. As there should be some inclination (3 deg) directly provided with the Class Surface for easy removal , we can report that for some modification in the Class A to have minimum 3 deg inclination on the face in zy plane.

7. Bisecting method on XY plane-

Using the axis system on the XY plane, Identify the faces that may create problems. Here there is two face at 90 deg with the base. Tooling Axis for X might be considered as the Perpendicular line with the base. As there should be some inclination (3 deg) directly provided with the Class Surface for easy removal , we can report that for some modification in the Class A to have minimum 3 deg inclination on the face in XY plane.

8. Create a Line normal to the Base with the point created using the base center and name the resultant line as Tooling Axis. Publish Tooling axis and A surface.

Resultant tooling axis normal to the Base

Procedure for Draft Analysis-

Step 1- Change the viewing mode to material mode.

Step 2- Click on draft Analysis and Select use the compass option to mount the Compass on the Tooling Axis.

Step 3- Select the Lock the draft option from analysis tool window and click on the Face of the component for which draft analysis is being carried.

Note that the area in Blue is incorrect and the face are at an angle of -.2.94. Because of this there is an error and modifications are required in the Class A surface.

Step 4- Set the Range and colour of Draft to set the ranges and colour codes of the draft.

Note that the range in not taken from 0 because the face are at an angle of -.2.94. In order to indicate the angle the above range is shown. To correct this error modifications are required in the Class A surface.

Step 5- Check the Inverse direction option for the mold opening and closing side as per your requirement

Step 6 - Use Analysis under the running point Option to check For The draft angle at a particular area which shows particular defect as per the colour code ranges.

Perform and check the draft colour scale gradient by setting parameters and perform draft analysis of the Class-A surface. If the component is clearing the tooling direction it will be displaced in a uniform colour (green) indicating that the surface will clear the tooling.

Draft Analysis of the Thickened Plastic Component-

Note that the area in Blue is incorrect and the face are at an angle of -.2.94. Because of this there is an error and modifications are required in the Class A surface.

Screenshots of the model with the proper color code of the draft angle in various orientations

Front-

Isometric-

Side View-

Top View-

Tree Structure-