Week 8 - Challenge 4 - Coin Holder Design

AIM: Create a tooling axis, Class B and Class C surfaces and perform draft analysis to tghe given Class A surface.

Class A surface: Class A surfaces can be defined as any surface, that has styling intent, that is either seen, touched, or both. A common method of working is to start with a prototype model and produce smooth mathematical Class A surfaces to describe the product's outer body. From this the production of tools and inspection of finished parts can be carried out. Class A surfacing complements the prototype modelling stage by reducing time and increasing control over design iterations.

Draft analysis: Draft analysis is the technique which is used to ckeck the catpart wheather it is designed on the basis of the draft condition. we are providing a direction in which components should eject inorder to get an easy removal of components from the tool. In other words it also lets us know whether the model is having a draft angle and how much is the draft angle from the tool direction. The major consideration of Draft Analysis is whether sufficient Draft Angle is provided on the component. Components while designing should be provided with a considerable amount of draft angle depending on the manufacturing consideration. For Plastic components we provide a draft angle of 3degree(Draft angle of 0.5 is given ideally to the features inside the plastic part). But for Automotive Sheet Metal Parts, it will be from 7 degrees or more.

Procedure:

• By using boundary tool check any openings are their in the given class A surface of centre console of given coin holder.
• Create a new geometric set and name it as tooling axis.
• Create a point at the centre of the base surface using extract surface and in point tool select on the surface.
• Create an Axis system at that point that is created on the surface.
• Now create an intersection in the ZY plane by Intersection tool for the Center Console Coin Holder.
• Now using Point-Point in Point Definition extend the line to take reference drafted lines on both sides and bisect
  those lines to get the direction in the ZY plane.
• Create an intersection in the ZX plane and create a Tooling axis in the Zx plane.
• Bisect those two tooling axis lines and create a Main Tooling axis and name the bisected line as Main Tooling Axis
  and do the draft analysis for the Class A surface.
• Now create the Plastic design for the given Class A surface of the Center Console Coin Holder by creating the Class
  B and C surfaces.
• Create a new Geometrical set in a tree and name it as B surface. Extract the side wall surface of the Center Console Coin Holder by Extract option by selecting the faces.
• Untrim the extracted surface using the Untrim option by selecting the surfaces.
• Extrapolate the Untrimmed surfaces using the Extrapolate option.
• Offset the surfaces to 2.5mm in the opposite direction to the Class A surface.
• Extract the base surface and block and do the same process and offset the surface to a distance of 2.5mm in
  downward direction.
• Trim the Excess portion of the surfaces using the trim option.
• Do the same process for inclined walls surface and outside wall surface by extracting and offsetting the surface
  and trim the component.
• Now do edge fillets to the class B surface to the required fillet radius.
• Create the class C surface for class A surface by using the Multi extract option by selecting the boundaries.Create
  a smooth curve for the extracted boundary.
• Replace the Multi extract boundary with the Smooth curve.
• Now using the Sweep option create the C surface with an angle 90 degrees to the surface.
• Join class C surface with class A surface and trim class B surface with the joinned surfaces of class A&C.
• Now using close surface in the part workbench create a close body for the coin holder.
• Perform the draft analysis for the closed body, check the draft angle with respect to the tooling axis, and make sure that the draft angle should be in green colour that indicates positive.

Class A surface:

Tooling axis:

Untrim base surface and create point with reference to the surface and create the tooling axis.

Class B surfaces:

Walls:

Extract surfaces and untrim it later extropolated the surfaces to intersect each other.

createing B surface for walls by giving offset

Base:

extract base and untrim it later do extroplate to the surface and create B surface by giving offset

untrim the other base surfaces and repeat the same process

now trim the surfaces which are on base

now trim base surfaces with the wall surafces

Top surface:

extract the top surfaces from the class A and repeat the process same to base and walls.

Outer surfaces:

Repeat the process of extract, untrim and extrapolate.

trim the unwanted surfaces

join the outer surface and top surface to the trim part of base and walls.

now do the fillet opertion using edge fillet

Class C surface:

Class C surface is created by using sweep tool with an angle with respect to the tooling axis

Join class A and class C surfaces

Trim the B surface and the join of A and C surface to remove the unwanted surface

using close surface create the solid part of the coin holder

Draft analysis:

Perform draft analysis to the solid part

Tree: