Week 8 - Challenge 4 - Coin Holder Design

Aim: To create coin holder plastic component design using given Class A surface.

Objective:

• To design Coin Holder as per the automotive OEM standards.
• Create Class B, Class C and Tooling direction.
• Converting closed surface into solid part with 2.5 mm Thickness.
• Perform draft analysis to verify toooling axis.

Introduction:

The input of the product design engineer is in the form of Class A surface. The job of designer to create Class B and Class C surface keeping all the manufacturing aspect in mind.

Design Methodology:

Procedure for tooling axis:

1. Intersect the model with the plane perpendicular to an axis system.
2. Extend the lines which are perpendicular to the molds.
3. Again, Intersect the model withanother plane and extend the lines perpendicular to it.
4. Create a bisecting line by bisecting option in line definition.
5. Rename it as Tooling axis.

Class A Surface:

Procedure for creating Class B surface:

Side wall:

• Extract the side wall with no propogation in extract option.
• Untrim them.
• Extrapolate the surface with point contuinity of 20 mm.
• Trim the walls with required shape.
• Offset those trimmed wall with 2.5mm thickness.

Top and Bottom Surfaces:

• Extract the surface seperately and untrim them.
• Extrapolate the surface with the required distance.
• Offset the with the 2.5 mm thikness.
• Trimmed them with required shape.
• Measure the fillete, calculate it and creat edge fillets.

Procedure for creating C surface:

• Get the boundary lines of class A seperately.
• Smooth the curve by smooth curve option as there are many vertices after boundary creation.
• Sweep the curve with perpendicular to the tooling axis direction in sweep option.
• As both line do not intersect , extrapolate them with the certain length.
• Trim the srfaces as per the requirements,

Procedure to creating closed body:

• Join the Class A and Class C Surface.
• Trim those surfaces with Class B Surface.
• Go to part workbench and create closed surface.

Draft Analysis:

Green colour represent the all the body surfaces neet the minimum 3 degree draft angle and Blue faces represent less than 0 degree angle of draft which act as a core side injection molding assembly.

Various Orientations

Isometric View

Front View

Side View

Top View

Conclusion:

Thus the plastic coin holder design is completed using generative shape design and part design workbench.