Week 8 - Challenge 4 - Coin Holder Design

REPORT - DESIGN OF COIN HODER PLASTIC PART

OBJECTIVE-

• To understand the design procedure of Coin holder plastic component by using SURFACE WORKBENCH in Catia V5.
• Lear to uses of draft analysis on coin holder to determine ejection of core and part during dis-assembling of mould.

procedure to design and draft analysis-

1. CREATE TOOING AXIS-In this step we have to build the tooling axis.tooling axis help to understand the draft analysis for mold opening.
2. DESIGN OF DOOR ARM REST- TO design Coin holder we have gone to various steps like creation of class A -surface,Class B,Class C respectively and create solid model eith the help of close surfaace
3. PREPARE DRAFT ANALYSIS REPORT- The draft report help to understand the easy disassemble of core and cavity.

A) PROCEDURE TO TOOLING AXIS-

1.TOOLING AXIS-

Tooling axis- mostly in mould design the by using main tooling axis we deside the location of core and cavity and part should be created along the tooling axis

1. STEP 1- Extacting the base surface from class A-surface.

2.STEP 2- Creating point on the surface and from that point draw the line normal to the surface which ensure the main tooling axis.

FEATURE TREE CHART-

B) DESIGN PROCEDURE OF COIN HOLDER-

STEP 1-Extracting boundary from CLASS A- surface.The multiple set of boundary present in Coin Holder so to easy surface design we have to extract it.

STEP 2- Disassemble the boundary group into individual boundary.

STEP 3- Creation of base surface of coin Holder

• extract the base surface along with side patch surface
• extrapolates both surface and offset the surfaces with 2.5 mm suitable distance.
• Trim the both surfaces and keep the usefull surface.

STEP 4- SIDE WALLS

• Extract side wall surfaces and untrim them.
• Extrapolate the surface with sutaible distance.
• Trim the surfaces and Offset them with 2.5 mm
• Apply the proper edge fillet on side wall surface.

STEP 5- Top wall

• Extract top wall surfaces by using multiple extract feature.
• Extrapolate the surface and offset it.
• Trim the surface.

STEP 6- INITIAL TRIM

1. Trim base and side walls
2. Trim the top wall with join of base and side wall.

STEP 7- Creation of Outer flange

• Extract the outer flange surface and offset it with 2.5mm
• trim it with initial trim surface to obtain the coin holder profile.

STEP 8- class B-surface

• Apply the edge fillets to gain the Class B surface.

STEP 9- CLASS C-SURFACE

• Extrect the outer flange surface to create C surface.
• Use the sweep feature withthe reference of flange surface with giving 90 degree direction.

STEP 10- CLOSE SURFACE

• Join the Class A & C surface
• Trim it with Class B-surface and obtain the close surface of coin holder.

STEP 11- CONVERT CLOSE SURFACE TO SOLID MODEL OF COIN HOLDER

• TO convert surface to solid body ,use the PART WORKBENCH go to close surface feature.

B) DRAF ANALYSIS OF COIN HOLDER-

*Procedure to create Draft Analysis-

1.Open the part file in Catia workbench.

2.Apply the material for part.For that go to view feature>Render style>Customize view parameter.

3.For draft analysis we have to select Insert>Analysis>Feature draft Analysis.Then there will be opening the Draft analysis dialogue box with showing icons like mode, display and direction.

4.Move the compass towards the tooling axis and coinside it with tooling axis.If you want to fix the compass then click on lock icon .

To start the analysis-

1.Select the surface of Part that we want to analysis.

2. click on draft analysis icon .

3.MODE OPTION-

In dialoue box showing mode option with quick & full analysis mode.In that mode feature we can understand the different angle range value in colour format which indicate part is in correct drafft mode or not.

The default mode is the quick mode. It simplifies the analysis in that it displays only three color ranges.

* QUICK MODE-

*FULL MODE-

* Doble click on color range which display in dialogue box and we can change the color range.

*Also by double click on the angle value ,we can modify it.

*The colour mode and respective Draft angle value is set in mode dialogue box.

• When the Draft angle value of the surface is equal or smaller than graduated (fixed in dialogue box) value,the colour will be applied as per graduated value to the surface.
• When the Draft angle value of the surface is greater than greatest value of graduated,the colour of graduated value is applied.

4.DISPLAY OPTION-

• color scale-This dialog box only appears in edition mode.Means we have to activate Full mode or Quick mode analysis.
• Angle Pointer-activate the pointer and move it over the surface which showing various draft value at different locations.

Arrows are displayed under the pointer, identifying the normal to the surface at the pointer location (green arrow), the draft direction (red arrow), and the tangent (blue arrow). As you move the pointer over the surface, the display is dynamically updated. Furthermore, circles are displayed indicating the plane tangent to the surface at this point.

• No highlighted & Representation icon-This feature gives option like on/ off the highligh portion of part.As it enable ,it will show all edges in colour (highlight) format.
• LIGHT EFFECT-This feature helps to understand the visualisation effect of part under light effect.This light effect will affect the visualiser's eye.
• Inverse direction- It allows to change the direction of draft angle of selected part.As the we click on reverse direction then there is changing gaduated colour effect ( in negative).It shows the BLUE colour.

5. DIRECTION -

1. LOCKED DIRECTION- In that we can lock or unlock the draft angle direction,a plane,a Face which is used in current analysis.
2. COMPASS- It is used to define the new or current draft direction.To set the compass direction on Tooling Axis,we have to move or pull the compass origin and coinside with tooling axis.

6.Once we have finished the analysing the surface by applying propper elements CLICK on OK icon in DRAFT ANALYSIS DIALOGUE BOX.The analysis is added to tree chart of part.

IN this way we can genrate the report for Draft Analysis for a given part by using Feature Draft Analysis.

The images of Draft Analysis are as follow-

1.Quick Analysis mode- with color scale variant & Complete draft Analysis

A) CLASS A-SURFACE-

B) SOLID BODY-

1)FRONT VIEW-

2)SIDE VIEW-

3)TOP VIEW-

2) FULL ANALYSIS MODE-

*FRONT VIEW-

SIDE VIEW-

TOP VIEW-

ISOMETRIC VIEW

*Different orientation views of coin holder with Class A,B &class C-surfaces-

***SUGGESTION- REWORK

• As applying draft analysis on Coin Holder plastic part,it show inside and top wall are in BLUE COLOR(ZERO DEGREE) & RED COLOR(Negative draft)
• So this will affect tighting effect or wear & tear effect on core.
• Therefore to easy ejection of part and core as well,we suggest to rework on CLASS A-SURFACE to give some POSITIVE DRAFT on side wall of Coin Holder part.

**RESULT OF ANALYSIS-

1.GREEN COLOR- Here Green color shows that the draft analysis is positive and there is no error in model.The angle nearly more than 3 degree is considered as positive draft angle.It indicate that core will diassemble easily without wear and tear

2.Blue & Red Color- Red and Blue color shows negative draft angle.It appears below the part upper surface that is not affect on core during ejection.

• BLUE COLOR- It indiacte exact angle of part geometry with ZERO degree.

*CONCLUSION-

we learn to create solid model in surface workbench with help of CLASS A,CLASS B AND CLASS C-surface,By using different feature like extract,untrim,trim,extrapolates,sweep etc..

In Draft analysis we can learn about provided draft angle is correct or not.Draft angle decide the part ejection from mold with smoothly.Draft analysis shows part whethere positive or negative draft angle.

Also we can learn how to generate Tooling axis with the help of intersecting the surface along with normal to surface and finally we create main tooling axis.

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