Week 9 - Attachment Feature Creation - Challenge 2

REPORT:

AIM: TO CREATE CLASS B AND CLASS C SURFACES AND DOG HOUSE ON THE COMPONENT

PROCEDURE: first we will recieve a class A surface as an input and we have to create the class B surace and class C surface for it and then we have to make it as a solid component and then we have to create the doghouse on the B side but before creating the class B surface we have to create the tolling axis.

 the most possible tooloing axis is Z direction but for this component we have tooling axis in the Y direction So we extract the surface and we create a point on the surface and we create a  line by point direction method and we create the line and we will name it as the tooling axis.

after creating the tooling axis we have to create the B surface for this component There are so many patches so we can't extract each one of the patches and then do the further operations Instead of doing all those operations we can offset the entire component to the required direction and the measurement.

after offsetting the entire component we will be having some gap between the components So we have to work on those components by doing multiple extract and then extapolating them And then giving the fillets value.

after working on the gap between the component we have to create class C surface by using sweep command with the draft direction and with the reference surface.

after getting the output as above image that is class C surface we have join the Class C surface with Class A surface and then the output will be as follows:

after getting the joint of class A and class C we have to trim the Class B with the joint of Class A and Class C

But while trimming it, the Class B surface is not properly intersecting with the join of Class C And class A to clear that problem we have to extrapolate the whole B surface a little bit and ensure that the B surface is intersecting with the join of Class A and Class C And you will get the output as follows:

after getting the proper intersection we have to trim the Class B with the join of Class A and Class C And we will get the output as follows:

to ensure that the our component is proper we have to put boundary on it If the boundary is not coming our component is correct. 

but the surface which we got is hollow inside We want it to be the solid surface So we go to the part work bench and we have to use the closed surface command to close the surface and we'll get the solid body and the output will be as follows:

after getting the solid component we have to make the doghouse for the component.

To create the dog house 1st will create a point on the specific area and we will create a plane on it and then we will create a sketch of the dog house with reference to that plane after creating the sketch we have to extrude it instead instead of extruding we can sweep it along the tooling axis by using drafting direction method because if you extrude it later we have to do the draft analysis for that Instead of doing the draft analysis the again and again we will create sweep with the tooling axis with minimum 3 degree angle the output will be as follows:

instead of sweeping it only one side we will give the second length ah as the two MM because the sweep has to insert into the main part body so that later we don't get any non intersections.

after sweeping it the top has to be closed to close the top surface we want a surafce to trim with it to getting that surafce we have to  extract the base and then offset it to the required height and then we have to use the trim command to trim it but here we have got a issue that the offset of extract is not trimming with the sweep so we have have to trouble shoot it. to trouble shoot it we have to create another sketch( a line ) to create the line we want a plane as reference to get that plane we will offset the first plane which we created to the required height and then we use the offsetted plane as refrence to the sketch and we will create the sketch and we will extrude it to the z direction so that the sweep and the extrude is intersecting and later we will trim it.

after trimming the top face we have to thicken the surface by using thicken command in the part work bench to the required thickness after that that we have to create the lower surface of it the lower surface should be 40% of the wall thickness so that for example our component is 2.5 MM thickness and the 40% of the 2.5MM wall thickness is 2.5*0.4=1mm. so the below surface height has to be between 3 to 6 mm.

CREATING LOWER SURAFCE:

to create the lower surafce we will create a sketch ( a line ) on the first plane and then we will extrude it to the z direction to intersect it with the dog house and we will offset that extrude it between 3 to 6 mm from the plane and  then we will extract the sweep with tangent continuity and then we will offset the first sweep to one mm to the required direction and then later we will trim the offsetted extrude with the offsetted sweep and we will get the output as follows:

after getting the output as above image we will use the split command in part workbench and then we will split the trim and we will get the output as follows:

after getting the output as above image we have to draft all the inner faces including the  to a minimal value of 0.5mm and we have to ensure that the material is cutting.

But for drafting the inner faces we want a side core tooling axis because it is going to be manufactured via side core so we will create another tooling axis with respect to the x direction.

to create the side core tooling axis we will create a line with respect to point direction method and we will use the first tooling axis point and create the side core tooling axis the out put will be as follows:

the pink coloured line is the side core tooling axis.

after getting the side core tooling axis we will draft the inner faces of the dog house with base as the support and the pulling direction as side core tooling axis and we will draft the inner face.

after drafting the inner face we will give the fillets to it and then finally we have to add it with the main part body but here we did the union trim because we have given the second length of the sweep longer than the wall thickness.

and then we will create another dog as we created the first dog house.

and at last we will do the draft analysis for the final compoinent and our output will be as follows:

for creating the draft analysis we will go to 

insert>analysis>feature draft analysis

after selecting feature draft analysis we will select the compass and drag it to the tooling axis and then we will lock it there and use the compass to check the drafting angles.

here we have got two colours one is green at top and the red at bottom which means the green colour indicates that the draft is more than 3 degree and the red colour indicates that the draft is less than 0 degree.

once if this all done our component is ready for manufacture.

DIFFERENT VIEWS:

TREE STRUCTURES: