Week 8 - Challenge 4 - Coin Holder Design
Aim: Creating the Coin Holder Plastic component through the given Class-A surface and performing draft analysis on both.
Description:
THE GIVEN CLASS A-SURFACE IS NOT DRAFTED (It has lines which are at 90 degree angle, marked in below snap), SO IT CANNOT BE EJECTED FROM CORE AND CAVITY BLOCK. WE NEED TO INFORM ABOUT THIS ERROR TO THE TEAM WHICH HAS CREATED THE CLASS A-SURFACE AND GET A MODIFIED CLASS A SURFACE..
Steps involved in creation of tooling axis:
1. Extract the base surface and create a point on that, then insert axis system on the point.
2. Using positioned sketch select the XY-Plane and enter the sketch mode. Now, use 3D intersect to trace the curve and then convert it to construction line.
3. Draw two construction lines at the inclined curves and create a bisecting line using these two lines.
Steps involved in creation of Class B-SURFACE:
Creation of Base:
1. Extract the simple surfaces (which don’t have fillet), untrim surfaces.
2. Extrapolate, offset and trim the surface to meet the required design..
Creation of side walls:
1. Extract the simple surfaces (which don’t have fillet), untrim surfaces.
3. Extrapolate and trim the extra portion.
4. Offset the trimmed surface and offset it to distance of 2.5mm.
5. Trim the filleted surface with the base.
Creation of Top Walls:
1. Extract the top portion, join them using "JOIN" command and offset the same.
2. Extrapolate and trim with the side wall surface.
Creation of Flange:
1. Extract the surfaces, join them and offset at 2.5mm distance.
2. Since the other two surfaces cannot be extrapolated, so I have extracted the other part and untrimmed it as shown in below snaps.
3. Join the surfaces, extrapolate, offset and trim as per requirement.
4. Trim flange with the top wall surface as shown below and fillets are applied on sharp edges.
As we can see in the above picture that a part is not cleared in trim option. For which, we will
- Extract that part from Class A-Surface.
- Untrim it
- Extrapolate in all direction
- Offset it to 2.5mm.
- Trim to get required surface
Fillets are applied at sharp edges, so that it prevents the injuries on workers while machining on them.
CLASS B-SURFACE.
Steps involved in creation of Class C-Surface:
1. Extract the outer boundary and the adjacent surfaces to that boundary.
2. Using "sweep with reference surface" a surface at 90 degree has been created as shown in below pictures
Where the outer boundary is profile and the extracted surface as reference surface. This is done in order to form a closed hollow surface.
3. Trim the above sweep part with Class B-Surface.
4. Follow last two steps for hole and finally trim it with the last trimed surface.
6. Finally, join the last trimmed surface with Class A-Surface and Class C-Surface is created.
Before making it solid component ensure the boundaries are closed.
CLASS C-SURFACE.
Steps involved in creation of Solid component:
1. Changing the window from "Generative shape design" to "Part design" and choose "Close Surface" from "Surface based features" toolbar.
2. Selecting Class C-Surface as "Object to Close" and solid part is created.
Steps involved in Draft analysis on Class A-Surface of Coin holder:
1. Select 'Customize view parameters' from the 'View mode' and choose 'Materials'.
2. Select 'Feature Draft Analysis' from the 'Analysis toolbar'.
3. Now, holding the red-dot, which is on the compass (present on Top-right corner of the window) align with the Tooling axis and lock it.
4. Set the Minimum draft angle (3 degree for plastic components) in 'Draft Analysis' dialog box (Which has different color bars).
5. Choose Class A-Surface of Coin holder as element in 'Draft Analysis' dialog box or Just click on the surface.
6. After selecting if the color changes to,
Green, then the draft of the Part has minimum draft angle of 3 degree.
Red, then the draft angle of the part lies between 0-3 degree.
Blue, then the draft angle of the part is less than 0 degree.
7. By choosing 'Analyse under running point' from 'Analysis toolbar' we can check the draft angle at any point on the surface just by moving the pin.
Steps involved in Draft analysis on Solid component:
1. Select 'Customize view parameters' from the 'View mode' and choose 'Materials'.
2. Select 'Feature Draft Analysis' from the 'Analysis toolbar'.
3. Now, holding the red-dot, which is on the compass (present on Top-right corner of the window) align with the Tooling axis and lock it.
4. Set the Minimum draft angle (3 degree for plastic components) in 'Draft Analysis' dialog box (which has different color bars).
5. Choose Solid component as element in 'Draft Analysis' dialog box or Just click on the surface.
6. After selecting if the color changes to,
Green, then the draft of the Part has minimum draft angle of 3 degree.
Red, then the draft angle of the part lies between 0-3 degree.
Blue, then the draft angle of the part is less than 0 degree.
7. By choosing 'Analyse under running point' from 'Analysis toolbar' we can check the draft angle at any point on the surface just by moving the pin.
Screenshot of solid component in different orientation:
1. Isometric View:
2. Front View:
3. Right View:
4. Left View:
5. Top View:
Class A, B, C and tooling axis are published so that it can be selected quickly for particular operations:
Conclusion: The Class A-Surface is not drafted and this creats problem in manufacturing process, so need to inform the team which has created the class A-surface and get a drafted surface .
Due to the error in Class A-Surface, the draft analysis results are not satisfied.