Week 9 - Attachment Feature Creation - Challenge 2

Aim: Create the screw boss and Dog House for the Centre console coin holder.

General Guidelines for Bosses:

• Draft - 0.5 degrees on walls of boss
• Thickness - Typically 40%* of the nominal wall at the base.
• Height to Diameter Ratio - 3:1
• Radii - 0.25mm maximum radii.

"C" is where the doghouse contacts the backside of the surface

• Doghouse wall thickness at the intersection of the part wall ( C ) should be 40% or less than the main wall stock ( T ).

• Height of ( B ) should be between 3.0 – 6.0 mm

Screw Boss: We already created a coin holder. Now, We have to create a screw boss which is one of the B-side features.
To create a screw bose draw a sketch on the base surface with a diameter of 5.2mm. For screw, the bose thickness should be 0.6 times the thickness of the main component, so it will be 8.2mm.

Make it pad by height/diameter ratio of 3:1.

Give the fillet of 0.25 mm to the lower base.

Draft the outer face of the boss to 0.5 degrees.

To stiffen the screw boss add the ribs on 4 sides by drawing the sketch on the base surface & pad it to a height not more than the rib height.

We take 1 mm thickness & 10 mm height.

Draft all the faces by 0.5 degrees.

Give the fillets of 0.25 mm to all edges.

take an axis system on top of the bose & intersect the XY plane with the overall part. After that union trims the ribs with bose.

Now, our screw bose is ready. Add the screw bose into the main body.

After that, we translate the screw bose on another side also & give the fillets of 0.25 mm.

TREE STRUCTURE FOR SCREW BOSE:

DOG HOUSE CREATION:
Create a sketch on the base surface where dimension should be more than screw boss.

For a dog house, one of the sides should be open, make one side a construction element.

Extrude the sketch using the sweep option with 1.5 degrees to the height of 20mm towards the top & 1 mm towards the bottom.

To cover the top surface offset the extracted base surface to a distance of 20mm & then trim it & fillet it by 1 mm.pad the extruded surface
outside with a thickness of 2mm.

Trim the surface with the extract

Now, create the tooling axis for the side core.

Draft the inner 3 faces with 0.5 degrees & give a fillet of 3 mm

Create backside contact surface by offsetting the extracted base surface to a distance between 3.6 mm height & sweep surface to a distance of
40% of main wall thickness. Trim both surfaces.

offset the inner face by 1 mm.

Split the offset Surface with the body to get the cut on the backside of Dog House. Draft the Split area with 0.5degrees and fillet the surface
with the radii of 1mm and then translate the Screw Boss to the top of Dog House and Add it to the Dog House and Add then component to
the Main component. Do the Draft Analysis on the final component in both tooling axis.

Draft analysis:
On dog house by using the main tooling axis.

BY USING SIDE CORE AXIS:

Final Component: