Week 8 - Challenge 4 - Coin Holder Design

TREE STRUCTURE OF COIN HOLDER

DRAFT ANALYSIS OF SOLID COIN HOLDER AND VIEWS

FRONT

SIDE

TOP

ISO

DESIGN AND DRAFT ANALYSIS REPORT OF COIN HOLDER USING CATIA V-5

OBJECTIVE: To design the Coin Holder using Surface Workbench and generate Drafting Analysis Report on the Class A and C using CATIA-V5.

DRAFT: When the molten plastic is completely ejected into the molded cavity and it is allowed to cool it tends to shrink to the core side of the mould and thus there deveolps a friction between the part [final output] and the mould. To overcome this drafting is required. It is required on all parts in the direction of mold movement in order to allow parts to release or eject from the mold properly.

Min draft required on final plastic component is 3mm.

DRAFTING ANALYSIS:

Drafting Analysis is used to generate computational analysis of the component clearing the mould cavity without any damage [by friction] between the final component. It checks whether the Main Tooling Axis is correct or not thereby analysing the draft of the component. It shows whether all faces of the component has the required draft or not using value assigned colour codes [pic 2]. It further helps us to detect corrections in the earlier stage [i.e design] thereby preventing the cost and damage to the component.

Draft Analysis Icon[01]

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At first the component is checked for any discontinuity in the line using two techniques. Namely,

1. Join Definition

2. Boundary Tool

However for Coin Holder we made use of Boundary Defintion Tool available in the Operation Toolbar.

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The above image ensures that the component has no discontinuity in line.

FORMULATION OF MAIN TOOLING AXIS USING BI-SECTING METHOD

TOOLING AXIS: It is an Axis which indicates the direction in which the mould/cavity opens. It can also help in designing the component according to the drafting standard of an Industry.

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BISECTING METHOD:

Bisecting Method is used to generate main tooling axis by bisecting or dividing the two dummy tooling axis generated from intersection of planes.

It can be created in both Workbenches.

[8] [9] [10]

[pic 10] - 1 and 2 are Dummy tooling Axis bisected using a Line using Line Definition Tool which gives us the Main Tooling Axis [no.3 in pic].

However in Coin Holder we make use of Line Definition Tool to generate Main Tooling Axis Normal to the surface.

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PUBLICATION

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Before Publication make sure in the View Mode Customization dialogue Box, Material box is checked which is available in the Mesh Subsection.

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DRAFT ANALYSIS REPORT OF COIN HOLDER USING CATIA-V5

At First, Compass Tool is used to position the co-ordinate plane into the main tooling axis of the component and locked using Lock Tool .

This compass tool is available in the drafting Dialogue Box along with Lock and Analysis under Running point Tool in the display section of the dialogue box.

A Red pointer [pic 15] appears on the component when the cursor is moved over the component under drafting analysis.

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1.DRAFT ANALYSIS OF CLASS-A SURFACE

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[pic 13] - shows Running point Tool to check the draft on the face.

Observation:

The angle between the Class A-surface [specifically Top wall and Base] and the Main tooling axis meets the requirement of Minimum drafting angle. To be specific the angle is > 3.

Another portion of the Coin Holder is Blue in colour indicating that the faces are inverted.

The Hole in the Side Wall requires another Tooling Axis to clear minimum drafting requirement.

The Side Wall is at 0 deg indicating adjustment of tooling Axis.

The above draft analysis shows that the Class A- surface clears the minimum draft requirement of 3mm on one portion specifically Top wall and Base.

COLOUR CODE IDENTIFICATION

RED	0 < A < 3
GREEN	0 < A > 3
BLUE	INVERTED

2.DRAFT ANALYSIS OF FINAL PLASTIC COMPONENT

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[pic 15] - shows Running point Tool to check the draft on the face.

Observation:

The angle between the Class C surface and the main tooling axis meets the requirement of Minimum drafting angle. To be specific the angle is >3.

The observations are found to be in line with the observation made in Class A Draft Analysis. Hence that surface can be proceed further to generate Solid Part of the Switch Bezel using closed surface Tool available in the Part Workbench.

Conclusion:

The Current Analysis highlights additional tooling Axis and some improvements where better drafting can be achieved. Hence the component can be moved further to the Manufacturing after incorporating the necessary changes.