Week 8 - Challenge 4 - Coin Holder Design

                                                                                                  DEAILED REPORT OF COIN HOLDER DESIGN

In this model of Coin Holder Design the following sections are we are going to do both practical and theoritical.

• Tooling Axis Creation
• Draft Analysis Report
• Design of the Part

Tooling Axis Creation 

To create a Tooling axis , start analys the model which section looking good to clear all the faces. One of type of creating a tooling axis by intersection method of xz and yz plane and using Bisecting method we have an mean line for the toooling axis. 

Intersection of YZ plane

In the YZ plane intersection we come to know there was no draft angle given in one sided of the wall it  looks staright 90 degre side. In Mouldibd parts parts without draft angle will look difficult for ejecting an component from the moulding. Hence, its a Class A component we cant do any changes here. We go according to the Class A model. 

Lets create an point in the flat surface of the model , make the surface as a exracted surface, use the feature as point on surface give distance has an 0mm for the center point of the surface. From there draw an line with normal to surface and make them as tooling axis line for the Coin Holder Part.

Draft Analysis for Class A

Do an draft analysis report on the givn class A surface, lets see how it works ithe compnent.

So, after applying the draft analysis as we know two face of wall has no draft angle in Class A. Hence the wall sided faces are not cleared they are below 0 degree.

DETAILED DESIGN OF A MODEL

CLASS B SURFACE

To create a Class B surface , its easy to model when we split each faces separetly and make a trim to join as a single surface . So, they are 3 sections to split in Class B

• SIDE WALL
• BASE
• TOP WALL
• OUTER FLANGE

Each faces are differentiated with a variant colours to look comfortbale for the design process.

SIDE WALL

To create a side wall extract all the flat faces of the model , untrim them and extrapolate to extend with all 4 side of the face intersect each other to make easy for a trim. Give an offset of 2.5mm give direction to the outward side of the Class A . 

Apply the required fillet radius to the wall, make sure that we shoul add the offset value to the given fillet radius, in order to maintain wall thickness 2.5mm. It was outer surface of Class A we should add the thickness value to the class B surface.

BASE SURFACE

Same as before extract the required base part untrim them and extrapolate to make a trim and offset to 2.5mm .

In the base we have to model a extra surface to complete the base. Extract the 3 sided flat faces , untrim and extrapolate to trim the surface with the base as a offset of 2.5mm.

TOP WALL SURFACE

Extract the top side walls using multiole extract to define as a single object and extrapolate on both side othe walls with an offset 2.5mm.

Intial Trim of Class B

• First trim the walls with the base surface to complete the lower portion of the model. 

• Next do trim them with the top wall surface.

OUTER FLANGE

In the flange they are tow sided flange are there, one is boundary side flange other is front taper which connects the outer boundary flange to form a complete surface.

Extract them and extrapolate to extend pass wall surface for trim operation.

Next extract the Front taper flange surface, in this stage it cant be extrapolated. So extract the each face separately , extrapolate and join the both extracted face. Then trim them with the boundary flange.

In order to trim the complete flane surface we need to extrapolate the front face surface to extend pass the walls, since its a unparalled face structure it is impossible to extrapolate them. So, we have to cut extra portion in the top sided face and make it as a parralel sided face to extrapolate.

To cut the extra portion, we can use solit option to do this. Draw a line along the down sided end of the boundary edge to cut parallel along to the downward portion and split them on both sided of the top face an offset of 2.5mm.

Trim with outer flange

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Complete Class B Surface

While checked the class B with Class A there was a some area has been left without trimed. So, before we finalise the class B trim we have to sort this out to get a complete Class B.

Extract the small area , untrim them and extrapolate through all area of top wall to trim the surface.

Now it was cleared with the Class A and the final Class B was completed.

CLASS C SURFACE

Class C surface is to be created by a sweep around the boundary lines of Class A with the multiple extraction method. Sweep as refrence surface feature with Class A as a refrence and angle be 90 degree.

Join the created Sweep with Class A surface inorder to form a Class c model.

Next we need to create a hole in the class C has in the class A. It can be done by creating a multiple extract boundary and sweep the boundary as with refrence feature, select the direction to outward side to trim it with Class B.

Apply the required fillet radius in the model to look a complete Class C model.

FINAL CLASS C SURFACE

PUBLICATION TOOL

After the completion of all surfaces, make them as a publication to get higlighted separetly its easy to get a required surface easily no need to look on the heometrical sets.

FINAL TRIM OF COIN HOLDER MODEL

Trim the CLASS C with CLASS A to trim unwanted extrapolated surface to get a complete coin holder part. After trim operation , move to part design section and make them as a closed surface to a complete solid part.

CLODSED SURFACE

DRAFT ANALYSIS ON PART MODEL

Apply draft analysis to the part model check the drafted angle of faces created between Class Aand Class C. As we already discussed in the Class A draft analysis model the side walls of the class A as no drafted faces. So we have created the model with  Class A model.

DIFFERENTIAL VIEWS OF DRAFT ANALYSIS MODEL

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

GEOMETRICAL SETS