Week 8 - Challenge 4 - Coin Holder Design

DRAFT ANALYSIS OF CENTER CONSOLE COIN HOLDER

Objectives:

To create tooling axis for the model

To create Class-A surface, Class B and C surface

To create CENTER CONSOLE COIN HOLDER & add thickness to it.

To perform draft analysis on CENTER CONSOLE COIN HOLDER part model

Steps of creation of Class-A surface of CENTER CONSOLE COIN HOLDER model:

Create a Class-A surface of COIN HOLDER by connecting different surfaces using JOIN or BOUNDARY command. Class-A surface will be seen yellow as shown in figure. Here I have given join limit 0.003 mm.

If any green line is seen between surfaces, it means that some discontinuity exists. To remove all gaps, use FILL option. Apply different colours to BASE, TOP WALLS, SIDE WALLS as well as OUTER FLANGE surface for identification purpose.

Steps of creation of tooling axis for Class A surface of CENTER CONSOLE COIN HOLDER:

After joining this model, a tooling axis is required.

Tooling axis is created for applying same draft over model regardless of position of surfaces on it.

First, extract BASE from Class A surface. Then select option called ‘On surface’ and give it a center point by selecting an edge of BASE & give 0 mm distance. Apply a new axis system on it.

Now create an intersection on YZ plane by using this new axis.

From the intersection, one can see that almost every section of Class A is parallel to Z direction without any inclination. It seems that there is 0 draft on surface model.

So, create a line in direction of Z at center point of BASE. This will be our TOOLING AXIS. Apply colour, thickness and line type to it.

Publish this Class-A surface of COIN HOLDER as well as TOOLING AXIS by using “PUBLICATION” from Tools menu.

Steps of creation of Class-B surface of CENTER CONSOLE COIN HOLDER model:

Consider thickness of part is 2.5 mm.

First, 4 Blue coloured SIDE WALLS are extracted from Class A surface. Then untrim & extrapolate them.

Use TRIM option to remove excess surface and then offset it inside about 2.5 mm.

Now, apply required edge fillets individually adding thickness of component.

After that, BASE part comes in process. It contains a flat surface & an inclined surface.

Both surfaces are extracted. Now, untrim and extrapolate them. Then offset it downwards about 2.5 mm.

Here, a small triangular step of 3 surfaces from Class A surface remained for extracting purpose. Untrim & extrapolate them as well.

Trim those 3 surfaces together. Offset this trim downwards about 2.5 mm.

Finally, trim this portion with other 2 surfaces in BASE.

Now, comes the TOP WALLS. Use Multiple Extract to extract those faces from Class A surface. Use boundary to extrapolate it. Then offset it outwards about 2.5 mm.

Here comes OUTER FLANGE surface. Use Multiple Extract to select surfaces around coin holder.

The biggest surface in OUTER FLANGE is extracted into two parts. These parts are untrimmed & joined together. Then extrapolate is used around 11 mm.

Same goes for other surfaces in OUTER FLANGE.

Then all the surfaces in OUTER FLANGE are given offset inwards 2.5 mm and trimmed together.

Now, this OUTER FLANGE is trimmed together with BASE, TOP WALLS & SIDE WALLS.

A small surface portion at one corner remained visible over this previous trim. So this surface is untrimmed and extrapolated for purpose of doing trim with previous trim. 2 mm fillet is given all over edges.

This will be our B surface. Rename this last fillet as “Class B surface” and use PUBLICATION to publish it.

Steps of creation of Class-C surface of CENTER CONSOLE COIN HOLDER model:

C surface is used for connecting Class A surface and Class B surface.

Here we are going to create C surface by using sweep with reference surface option.

First create a boundary from Class A surface & also extract outer flange surface as a reference surface.

Now create a sweep surface by using sweep with reference surface. Use boundary and reference surface & give length about 4 mm for trimming purpose and angle about 90 degrees.

For Hole, select boundary of it from Class A surface and use surfaces around it as reference surfaces. Now, apply sweep with reference surface again. Notice that its direction must be outward and should be cutting B surface.

In this way, C surface is created.

Now, join Class A surface with a C surface. Trim it with Class B surface and name it as final trim. Apply required fillets. Check any gaps remained in this final trim by using boundary option.

In part design workbench, use close surface to generate solid CENTER CONSOLE COIN HOLDER part from Class C surface.

Steps to do draft analysis on CENTER CONSOLE COIN HOLDER model:

Go to insert > analysis > feature draft analysis or directly click on Feature draft analysis icon from menu.

First select compass option from pop-up menu to set axis system coincide with tooling axis.

Here change position of TOOLING AXIS by moving compass location and use lock option to fix it to give every surface a proper draft.

Surface model will turn into green colour surface, which shows that draft for model is in limit upto 3 degrees. Here I have given green colour for 3 degree draft, light blue for 0 and red colour for negative draft.

Run quick analysis on model and if any draft angle is more than limit, then one can apply new value of it in pop up box.

Full analysis shows different draft angles with different colours as shown in figure.

Here is an example of INVERT DRAFT DIRECTION analysis.

Below image shows the different views of draft analysis of CENTER CONSOLE COIN HOLDER model.

Here are snaps of feature tree of this CENTER CONSOLE COIN HOLDER model:

Conclusion:

I have learned about tooling axis creation, Class A, Class B & Class C surface creation and draft analysis for given CENTER CONSOLE COIN HOLDER model in this challenge.