Week 9 - Attachment Feature Creation - Challenge 1

RIBS ON COIN HOLDER

OBJECTIVE:

• Analysing the class A surface given as input.
• Create the tooling axis for the core and cavity opening and ribs draft analyis.
• Create the B surface for the given class A surface.
• Create the C surface with the help of class A and class C surface.
• Creating the solid closed component with the help of closed surface based feature.
• Creating the ribs on the part.
• Checking all the design rules for rib creation.
• Draft analysis of whole component

1. CLASS A SURFACE

The class A surface is the surface created from the concept sketch in the software called AutoDesk ALIAS, the class A surface is basically the styling surface and it is used as reference by the product designer to design the component with the help of tooling axis and draft analysis, here we have switch bezel as a class A surface.

2. EVALUATING CLASS A

After receiving the class A surface the next step is to affirm about the closeness of the class A surface means make sure the class A surface is closed properly and there is no open surface which will hinder the analysis procedure in subsequent processes.In catia you can acknowledge this by using the Join and Boundary command .

3 . TOOLING AXIS CREATION

1. Tooling axis plays important role in plastic product manufacturing and designing, this axis decides the direction in which mould is going to work while production of the component.
2. The main focus while deciding the tooling axis is clearing the component in the moulding in the same axis with the minimum use of the side core for producing the component, the side core usually adds up to the cost of the component.
3. For the particular component X,Y and Z can be the possible direction for the tooling axis.
4. You must specify the axis system by creating the point on the surface.
5. With the help of the intersect in the YZ plane create the tooling axis in YZ plane .
6. With the help of the intersect in the ZX plane create the tooling axis in ZX plane.
7. The last step is to bisect the two tooling axis to obtain the main tooling axis of the class A surface.
8. Here the component is flat with 0 draft angle so line perpendicular to centre is tooling axis .

4.CREATING THE B SURFACE

1. The B surface is the surface where all the necessary attachments and supports are made for the component.
2. The B surface is created using the class A as reference and extracting the major surfaces without the edge fillets.
3. The extracted surfaces are then extrapolated to get the better view for trim,then offset these surfaces to the thickness of the component and then trimming the surfaces to get the B surface.
4. The necessary trimmed surface must contain the edge fillets as class A surface.
5. The edge fillets provided to B surface must be given properly to maintin the constant thickness throughout the component so as to avoid the flow line defects.

5)CREATING THE C SURFACE

1. The C surface is the surface which is responsible for providing the thickness to the component.
2. The C surface is the intermediate between the class A and class B surfaces.
3. The C surface is created by extracting the class A with a boundary .
4. The surface closer to the boundary is extracted and utilized for the sweep command.
5. The reference curve section is selected for the sweep with the surface closer to it as reference surface and sweeped at 90 degrees inward
6. Join the class A surface with the class C and then trim the join with the class B to obtain the final thickness component, here the thickness is 2.5 mm.
7. Use the boundary command to ensure surface is closed and there is no multiple boundaries , you can alter if any by increasing the merging distance till 3 microns.

6)CLOSED BODY CREATION:

1. Closed body is the body created in the part workbench with the help of surface based feature in the insert section.
2. The draft analysis is done on this close body.

8)CREATING RIBS ON THE HOLDER

1. Ribs plays vital part in any component at serves the purpose of proving stiffness and strength to the component it minimal sink to the class A surface.
2. Design rules should be strictly followed for the creation of the ribs.
3. EXTRACT the surface where ribs need to be created.
4. Create the sketch and make sure sketch is iso-constrained.
5. Extrude the surface to the height and make sure you extrude 1mm into the surface to avoid future problems .
6. Thick the rib following the design rule.(WALL THICKNESS= 0.4XCOMPONENT THICKNESS).
7. Provide the draft and fillets following the design rules.(DRAFT =0.5 DEGREES & FILLET +0.25XTHICKNESS OF COMPONENT ).
8. Create another rib by maintaining 3:1 (height to wall ratio).(here 5mm).
9. Intersect the component with the plane / or axis to obtain the intersection .
10. Calculate the root circle radius and make sure it follows (1.25 thickness of the component).

7)DRAFT ANALYSIS OF THE AND FINAL BODY WITH RIBS :

1. The draft analysis is done to ensure that the draft in permeasible with the design consideration.
2. The draft analysis is done by changing the visualization mode to customize and select shading as material.
3. The draft based feature enables us to visualize and examine the draft.
4. The draft window is has two tables one is for examining the draft and other one is the colour code.
5. The draft value is set in the colour code window with each colour having their own significance.
6. The red colour indicates the positive draft less than minimum draft where as the green colour indicates the minimum draft.
7. The blue colour indicates the negative draft.
8. For visualizing the draft the compass is aligned with the tool axis direction and the cursor is then made clicked upon the surface for viewing the draft.
9. The quick view in display window enables to examine the draft value throughout the surface.
10. Here both class A is given the minimum draft as 3 degrees.
11. The body with ribs is given the minimum draft value as 0.5 degrees.
12. The tooling axis for both the components will remain same.

CLASS A

CLOSED BODY WITH RIBS:

6) RIBS IN VARIOUS VIEWS

• ISOMETRIC VIEW

• FRONT VIEW

• LEFT SIDE

• RIGHT SIDE

• TOP VIEW