Week 8 - Challenge 4 - Coin Holder Design
AIM:
To Create the Coin Holder Plastic component through the given Class-A surface using Catia V5.
OBJECTIVE:
- Create a tooling axis following the OEM standard
- Making the Surface into Solid Body
- Part Thickness : 2.5 mm
- Performing the draft analysis to the component
INTRODUCTION:
The black plastic coin holder conveniently holds loose change in an organized manner. The compact design fits anywhere in your vehicle. The small coin holder easily installs with a magnetic attachment or hook-and-loop tape to keep it secure. Perfect for toll ways & parking meters.
The coin holder is manufactured in one-piece black polyurethane with left and right design. The material is soft, extra durable and can be easily cleaned and dried.
METHODOLGY:
- Creating the Tooling Axis
The tooling direction is used to find the direction in which the part is removed from the core and cavity. The draft angle should be positive to the tooling axis to manufacture the component easily. The step by step procedure of creating the tooling axis is given below.
Step: 1
Creating the point on surfaces respectively also extract the surface of the component.
Step: 2
Now creating the intersection to the Z-Y and Z-X direction of the surface as shown below.
Step: 3
It is symmetry and normal surface, hence we can directly by zero distance value based to normal to the surface.
Finally we get our main tooling axis for the door arm rest component.
- Creating the B surface.
Step: 1
Creating the B-SURFACE by extracting the class A surface, by each surfaces separately, it is untrimmed and extrapolated to certain distance using point continuity for uniform extension all over the boundary as shown below.
Step: 2
The extrapolated surface are offset for 2.5 thickness and it is trimmed out to form box shape.
Step: 3
Trimming the Side wall of the bin part to the main surface to get exact component as class A surface it is offset to the 2.5 mm distance.
Step: 4
Top surface is extracted, offset, extrapolated and trimmed along the side walls as shown below. Edges are again fillet to get aesthetic component.
Step: 5
Now the Base and top wall is get trimmed to combine the both surface into one surface part.
Step: 6
For outer flange also same method followed by extracting, extrapolating and trimmed to get single part surface.
Finally we achieved the B class surface by extracting in the Class A surfaces the edges of inner surface are get filleted for 2mm shown below.
- Creation of C Surfaces:
Step: 1
Extracting the boundary of Class A surface and it is make into smooth curves to sweep the curves by using support surface to the 90 degree respectively.
It is trimmed with b surface to make Class C surface as shown below.
Step: 2
Once the all surface joined together it extrapolated to certain distance to trim with Class A surface to C surface. Finally we created Class C surface.
Making the Final plastic Component:
To make the final component the Class C surface is trimmed with Class B surface, the output will get the component with 2.5 mm thickness of surface and it is converted into solid body using insert body option in part design as shown below.
- Performing Draft Analysis:
The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed component where the deviation from the draft direction at any point, corresponds to specified values. This rule of thumb applies to parts with mold depths of up to 2 inches. At this size, draft as low as 1½ degrees will allow for an easy, non-damaging release from the mold when the expected shrinkage of the thermoplastic material occurs.
It’s also important to remember that draft angles are just one component of an effectively designed injection molded piece. Design for manufacture is one of the easiest ways to improve the quality and efficiency of your injection molding process, and it never hurts to stay up to speed on all injection molding best practices.
- Draft Analysis for Class A surface:
Step: 1
Initially we perform the draft analysis to the class a surface to ensure that we have good quality of surface to make Class B and C surface to achieve the same kind of quality surface. First we have to set the compass on the main tooling axis to get the direction of core and part moves along as shown below.
Step: 2
Once compass is locked in the axis, directly click on the surface it will appear quality of draft surface whether, it is pass or failed. Here the draft angle is given as 3 degree. Hence we achieved green colour on top surface. Hence it accepts the draft angle for the surface, so we build good quality component
Step: 3
Now we check colour variant scale to ensure the maximum and minimum area draft angle is achieved by displaying by green, red and blue colour respectively. If the surface appears red in colour while analysing it is not accepted.
Step: 4
We can check the angle of draft given to surface by using draft tool analysis just point the over the surface where we have check angle of given draft to the component as shown below.
2. Draft Analysis for final component:
Step: 1
First we have to set the compass on the main tooling axis to get the direction of core and part moves along as shown below.
Step: 2
Once compass is locked in the axis, directly click on the surface it will appear quality of draft surface whether, it is pass or failed. Here the draft angle is given as 3 degree. Hence we achieved green colour on top surface. Hence it accepts the draft angle for the surface, so we build good quality component.
Step: 3
Now we check colour variant scale to ensure the maximum and minimum area draft angle is achieved by displaying by green, red and blue colour respectively. If the surface appears red in colour while analysing it is not accepted.
Step: 4
We can check the angle of draft given to surface by using draft tool analysis just point the over the surface where we have check angle of given draft to the component as shown below.
Screenshot views of coin holder with draft analysis:
Front View:
Side View:
Top View:
Isometric View:
Publication:
Conclusion:
Creation of the Coin holder has been successful done for the thickness of 2.5 mm, it has been converted from surface into solid body. The tooling axis has been created according the OEM standard. Drafting Analysis has been performed and results has been updated in step by step methodology. Hence we created perfect final coin holder component for manufacturing.