Week 9 - Attachment Feature Creation - Challenge 1

Aim: Creating the rib for the Centre console coin holder considering the design rules. 

Description:

THE GIVEN CLASS A-SURFACE IS NOT DRAFTED, SO IT CANNOT BE CLEARED IN EJECTION. WE NEED TO INFORM THIS ERROR TO THE TEAM WHICH HAS CREATED THE 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.

 

2. Extrapolate and trim the extra portion.

 

3. Offset the trimmed surface and offset it to distance of 2.5mm.

 

4. 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. Extract the other part, since it can't be extrapolated, so just untrim the surface after extract.

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

 

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.

 

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.

5. Finally, join the last trimmed surface with Class A-Surface and Class C-Surface is created.

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.

Class A, B, C and tooling axis are published so that it can be selected quickly for particular operations:

 

Steps involved in Rib creation by following design rule:

Ribs are created using the following guidelines and numerical values.

Numerical values used in the rib design by following the design rule.

• Thickness(t) = 2.5mm
• Rib draft = 0.5 degrees (because it is the min value)
• Rib fillet radius(r) = 0.25mm
• Rib root thickness should be > 30% of Thickness
• Rib thickness(w) = 0.4*2.5 = 1mm
• Rib depth = 5*2.5 = 12.5mm (considering the min value)
• Spacing distance between two ribs can be calculated using the relation,

 

       Rib depth/ Rib thickness `<=` 3

    Equating the Rib depth (w=12.5mm) and considering the ratio value=3mm and we get

        W = `12.5/3`= 4.166mm

1. Extract the surface and offset the plane to the surface (so that we can create sketch for rib on the bottom surface).  

2. Extrude the sketch to heigh of 12.5mm along the tooling axis and change window to part design and give thickness to the surface.

3. Using Boolean operation assemble the thickened part to the part body which is created in separate part body. Then provide the draft of 0.5 degrees and fillet of 0.25 radius.

Follow the above steps and create another rib at a distance of 4.1666mm as calculated above.

Rib design analysis:

1. Using intersection option create intersection curve with the part body and XY-Plane.

 

2. To check the Rib root thickness by creating circle at the root of rib. And using the measure tool measure all the values whether they satisfy the Rib design rule.

 

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 the Component with ribs in different orientation.

1. Isometric View

2. Front View

3. Right View

4. Left View

5. Top View

 

Conclusion:

            The Class A-Surface is not drafted and this creates 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.

And the rib created satisfies the rib design guidelines.