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 closed 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

Boundary Condition:

• Check the connectivity for the given Class A surface.

Creating 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 as Tooling Axis.

Creating Class B Surafce:

Side Walls:

• Extract the side walls with no propagation in 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 required shape.
• Measure the fillets, calculate it and create fillets.

• Joining all the walls by trimming option to form Class B.

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 tooling axis as direction in Sweep option. . As both lines do not intersect, extrapolate them with a certain distance.
• Trim the surfaces.

Joining Class A+B+C Surfaces:

• Join the Class A and Class C surface.
• Trim those joines surfaces with Class B surface.

Creating Close Body:

• Go to the part design and click on close body option to form a close body.

Different Views:

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 on tooling axis.
• Make sure that the top surface is in green colour as draft angle should not exceed 3deg.
• Click on Okay after confirm the model.

Class A Draft Analysis:

Final Body Draft Analysis:

Note:The given class A surface is not having proper draft analysis so that Class A designer should take care of it.

Tree Structurer:

Conclusion:

• Thus the solid model of the coin holder is created and draft analysis is performed on the model using the main tooling direction and the side core tooling direction.