Week 8 - Challenge 4 - Coin Holder Design

AIM - To Create the Coin Holder Plastic component through the given Class-A surface and to perform the draft analysis on the model.

PROCEDURE - Here Class A Surface which is given to me is shown below:

Now from the above-shown fig. I have to create the solid component creating the CLASS B and CLASS C surface. so first I will create the tooling axis.

The tree structure of the model is shown below:

Tooling axis - The tooling axis is defined as the direction in which the mold opens or core and cavity opens and closes. The selection of the correct tooling axis is important to ensure the component is taken out perfectly and also the cost of the component should be less.

I will start by inserting a geometrical set and naming it as a tooling direction. For creating the tooling axis I will analyze the model and see from which direction I can see the whole model. so here the direction I have chosen for the tooling axis is along y-direction because along y-direction the whole model is visible properly.

For creating the tooling axis first I will extract the base from the class A surface. And will create a point on the center of that base. Then I will insert an axis system on that point. since I have chosen the Y direction as my tooling axis I have to make sure that the tool should clear in both x and z-direction. so for x-direction, I will not create an intersection because there are no surfaces that would cause a problem during ejection. But for z-direction, I will create an intersect. The intersection parameters are shown below:

Here in the above fig., u can see that there are some lines that would not be perpendicular to the tooling axis but it will not cause any problem because most of the lines are drafted outwards so they will not intersect with the tooling axis. so for creating the tooling I will just simply create one line along the y-direction which will be my tooling axis. The tooling axis is shown below:

Now after creating the tooling axis I will create the Class B and Class C surface.

Class B surface -

It is a surface that gives thickness from class A surface. All the supporting features of the component will be formed on the B surface only. so we can say that Class B is an engineering surface and Class A is an aesthetic surface.

For creating the B surface first I will insert a geometrical set and name it as B surface creation. I will start by extracting the surfaces so first I will extract the sidewall surfaces. The extract is shown below:

Then I will untrim this and extrapolate to the extent to which all the walls intersect each other. The untrim is shown below:

Then I will do the trim and trim the extra portion of the walls and then offset outward to 2.5 mm because 2.5 mm is my thickness.

After that, i will create the base following the same procedure as I did for the walls. So I will extract the base surface and untrim it. The extraction and untrim are shown below:

Then i will extrapolate and trim with the walls

Then i will create the top walls again following the same procedures. the extract and extrapolation of the top walls are shown below:

then I will offset it and trim it with base and walls

Then i will create the outer flange. For this also i will extract the surfaces and extrapolate the surfaces. The extract is shown below:

Then i will offset it and do the trim

Then i will trim it with walls and base

Then i will provide all the required fillets to the sharp edges of walls and base. the fillets are shown below:

so after providing the fillets i will get my B surface. The B surface is shown below:

After creating the B surface i will create the class C surface from the class A surface

CLASS C SURFACE - Class C surface is defined as the surface which connects the CLASS A and CLASS B SURFACE along the tooling direction. The tooling direction here will be my tooling axis.

For creating the Class c surface i will create multiple extracts of the boundary. the parameters are shown below:

similarly, i will extract the side surfaces

Then I will perform the sweep. The sweep profile type will be a line type and the subtype will be a reference surface. The sweep parameters are shown below:

Then I will create the hole on the B surface so that also I will extract the boundary of the hole using multiple extract. the extract is shown below: and also I will extract the surfaces that surround the hole

And again do the sweep. the sweep parameters are shown below:

Then i will trim it with the b surface to get the hole:

After this, i will join the C surface and A surface. The join parameters are shown below:

Then i will trim The class B surface with the Join of Class A and Class C surface. The trim is shown below:

so now i have a close surface and i will create the solid body from the close surface in part design. The solid-body part is shown below:

After forming the solid body i will perform the draft analysis on the model.

Draft analysis - Draft analysis is a technique to analyze whether the component created is manufacturable or not based on the draft conditions applied. So here I will provide the direction in which the component should be ejected to get the easy removal. My direction will be the tooling axis that I have created.

The minimum draft value for the Automotive plastic component is 3 degrees and those for the texture faces 7 degrees od draft is suitable. The draft is provided to the component for easy removal from the mold in the case of a plastic component.

So here I will change the customize view parameters and will select the material mode.

Then I will go insert and select the analysis and in the analysis, I will select the draft analysis. The draft analysis block is shown below:

In the above fig. under the display, section select the color scale and turn on the light effect for proper visualization. then under the direction section, i will click on the compass and will drag the compass from vehicle zero to my tooling axis. and then I will click on the lock feature and will select the class a surface. The result is shown below:

The color scale is shown below:

In the above fig. The Green color shows that the draft provided is more than 2.9 degrees

The Red color shows that the draft provided is between 0 and 2.9 degrees

The Blue color shows that the draft provided is negative.

RESULT - The creation of coin holder part is done and the draft is also done and the result is shown below:

In the above fig., u can see that the part which is in green color is drafted with more than three degrees but there are parts that are in red and those parts have zero drafts. so the class A surface here is not provided with the proper draft so correct draft analysis is not possible.

CONCLUSION - This concludes the creation of the Coin Holder Plastic component through the given Class-A surface and draft analysis on that model.