Week 9 - Attachment Feature Creation - Challenge 2

Project Title : ATTACHMENT FEATURE CREATION  Challenge-2

AIM : Create the boss and dog house for the center console coin holder considering the design rules

OBJECTIVE :

• 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 dog house contacts the backside of the surface.

                                

•  Dog house 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 - 6.0mm.

DOG HOUSE DESIGN :

• Extract the base of the Class-A surface and offset it with part thickness as 2.5mm.
• Draw sketch of rectangle and should be open from one side for dog house.
• Using sweep with tooling direction and draft it at an angle of 1.5 degree for outer surface.
• Close the upper surface face bt offsetting the below extracted surface and after trimmed it.
• Convert the dog house surface in thickened surface by applying part thickness as 2mm.

                 

• Now for the inside face of dog house we need side core tooling axis created it in Z direction.
• Given draft to the inside surface of 0.5 degree.
• Now to create the C and B section as shown in design rules,  offsset the base surface in between 3 to 6mm.
• Extrapolate the surface to achive desired length.
• Switch to part workbench and split the C and B section with thicken part.
• Again, provide draft to the inside surface.
• Given radius/fillet to inside as 0.4*T=0.4*2.5=1mm and for outer edges give fillets as inside radius+part thickness and add minimum fillet of 0.5mm.

                         

• Assemble with coin holder main body.

                         

Draft Analysis of Dog House :

Screw boss design :

• Screw boss can be on B surface or it can be on dog house in this we are mounting it on dog house.
• Draw circular sketch inside circle of dia 5mm and for outer circle wall should be 0.6*T on one side so outside dia = 2*(0.6*2.5)+5 (inside dia) = 8mm.
• Pad it with main tooling direction considering height to dia ratio of 3:1.

                        

• H=B*3 = 5*3 =15mm.
• Given draft of 0.5  degree with tooling axis.
• Now to support the screw boss we need to given ribs for it.
• Draft to ribs of 0.5 degree.
• After that do union trim with screw boss and assemble to coin holder main body.

                      

Screw Boss Draft Analysis :

Views Of Final Body Analysis :

• Front View

           

• Back View

           

• Left View

         

• Right View

          

• Top View

               

• Bottom View

              

• Isometric View

          

Design Tree Structure :