Week 8 - Challenge 4 - Coin Holder Design

Coin Holder Design (Challenge-4)

What is Generative Shape Design?

The Generative Shape Design provides an extensive set of tools for creating and modifying mechanical surfaces used in the design of complex shapes or hybrid parts, Its feature-based approach offers a productive and intuitive design environment to capture and reuse design methodologies and specifications. It helps to design advanced shapes that are based on a combination of wireframe and extensive multiple surfaces which includes high-level features with full specification capture and reuse.

What is Draft Analysis?

The Draft Analysis command enables you to detect if the part you drafted will be easily removed, this type of analysis is performed based on color images identifying zones on the analyzed element where the deviation from the draft direction at any point corresponds to specified values.

No parts can be ejected from the tool if it is having a straight 90-degree profile from its base surface, a small draft angle is provided to each area of the component to get easy removal of the component from the tool. The draft analysis technique is used to analyze whether our part model created in cad is manufacturable based on the draft condition applied.

In the molding process, the molded parts have to eject from the die so there are some issues while removing the molded parts it may get sticky with the die, or while removing the chances to get damaged, so we need to set up is the draft angle this draft angle helps the molded part to eject from the die easily.

What is Class A, Class B, Class C Surfaces?

Class-A Surface: Surfaces made by the designer which is given as an input to the plastic modeler to work on, it is aesthetic surface and the outermost surface.

Class a surface Img

Class-B Surface: Surfaces made below a certain thickness from the Class-A surface is Class-B surface. This is the surface that contains engineering aspects of the model.

Class-C Surface: Surfaces that join Class-A and Class-B surfaces is Class-C surface.

Methodology

In this Coin holder Design creation, we have the CLASS A surface given to us, so we focused on few things:

1. Tooling Axis:

• Intersect the model with the plane perpendicular or to an axis system.
• Extend the lines which are perpendicular to the plane.
• Again, intersect the model with another plane and extend the lines perpendicular to it.
• Create a bisecting line by bisecting option in Line Definition.
• Rename it Tooling Axis.

2. Draft Analysis:

The Draft analysis for a 3 Degree draft is done on the Class A surface, so can be seen all the surfaces are more than 3 Degree of the draft.

3. Class-B Surface:

• Extract the side walls with no propagation in the extract option.
• Untrim them
• Extrapolate the walls with the point continuity of distance 20mm.
• Trim the walls to get the required shape.
• Offset those trimmed walls with thickness value.
• Now, extract the surfaces separately and Antrim them.
• Extrapolate the surfaces with required distances.
• Offset them with thickness value.
• Trim them for the required shape.
• Measure the fillets, calculate them and create fillets.

4. 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

5. Making a solid model from a surface:

After completing the previous step, go to PART DESIGN, and use the closed surface feature to close the model.

6. Draft Analysis on the Final Component:

To perform Draft Analysis on the model, go to the menu bar > select insert > Analysis > Feature Draft Analysis.

To give draft direction, use the compass and align it with the tooling axis which we created for the model, once it is properly aligned, select the surfaces of the model which will show us the draft angle given on the component is having a 3 deg draft value (green color). If the draft value is negative (component showing color in red), we need to adjust the tooling axis direction with the help of a compass.

TREE