Challenge

Week 9 - Attachment Feature Creation - Challenge 2

GGowthaman G11 Aug 2022

DESIGN

DESIGN AND DRAFT ANALYSIS OF DOG HOUSE

AIM

To create Dog house then add thickness to it and generate the Draft Analysis on a solid surface as final component.

TOOLING AXIS

Creating the tooling axis :

The tooling direction is used to find the direction in which the part is ejected out of the mold or it is the direction in which the core and cavity are moved and the part is ejected.
The draft on the part should be positive in order to manufacture the part easily. The draft angle should be positive with respect to the tooling direction.
To create the tooling axis, we need the proper orientation or view that gives the correct features and draft available in the component.
So here the component view from the Y-direction gives the proper view for the tool to see the features present in the geometry.To create the tooling axis from the Y direction we nee the tooling axis from the other direction that gives the wall draft angle.

The bin base center will be the initial tooling axis for the coin holder.

The tooling axis created by following steps

The base surface is extracted.
Then the center point is created using the point > on the surface at 0 3. At the point created the axis system is created.
After that switching the view of the model to the X direction and creating the tooling axis.
Using the intersect in the ZY plane to get the boundary lines. Then the lines are created along the slant surfaces.

SIDE CORE AXIS

CREATING DOG HOUSE

Create a sketch on the extracted base surface where the the dimensions should be more than the screw boss.
As for the Dog house one of the sides should be opened,make one side as a construction line.

Extrude the sketch by using the Sweep option with the 1.5 degrees to the height of 20mm towards top and 1mm towards bottom.

To cover the top surface,offset the extracted base surface to a distance of 20mm and then trim it and fillet the edges with 1mm.Pad the extruded surface to outside with the thickness of 2mm.Create the tooling axis for Side Core(Pink).

Create thickness of 2mm

Cut the uneven surface at the open side by extracting the opposite surface and offset it to a distance towards the open surface and split the part in Part design by using the Split option.

Draft the inner walls with 0.5 degrees.Now create backside contact surface by offsetting the extracted base surface to a distance in between 3 - 6mm height (B) and Sweeped surface to a distance of 40% of the main wall thickness(C).Trim the surface.

Split the offsetted Surface with the body to get the cut on backside of Dog House.Draft the Splitted area with 0.5degrees and fillet the surface with the radii of 1mm and then translate the 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

To perform the draft analysis the view parameters are first set to material mode.
Then go to Insert >>analysis>>feature draft analysis.
First, select the axis system and drag the axis system to align and coincide with the tooling axis and lock the orientation. This axis system defines the draft direction according to the tooling axis.
Switch on the color scale and set the minimum draft value. Here it is set to 3 degrees and i will be displayed in green color.
Any draft angle below 0 degrees will be shown in red color Now select the running point tool to measure the draft angle at the various locations and then if all surface passes the draft analysis switch on the light effect that will show the component in green color if the component has the required draft angle.
The final draft analysis shows the green color surface having the draft angle above 3 degrees and red or cyan color shows the draft angle below 0 degrees.
All the surfaces with green can be easily manufactured with the injection molding but the read color surface which is a negative draft cannot be ejected or manufactured with the main tooling axis.
The solution for this is to have another tooling axis that captures all the rest surfaces but this is not feasible or the last option to make changes in the A-class surface.
First, extract all 4 surfaces of the sidewall of the coin holder.
Then these surfaces are first untrimmed to get the intersection for surfaces so that a replica can be created.
If the surfaces are not intersected, then extrapolate by point continuity propagation is used to make these surfaces have an intersection between them
Lastly, the surface trim is used to get the replica for the inclined surface.
Now, the thickness of the final component is 2.5mm so this obtained surface is offset below by 2.5mm.
Like that the rest of the region is extracted and trimmed to get the final B surface.
The A-class surface has to measured using the measure between option and the value fo the fillets obtained is 9 and 10 and the fillets are provided by reducing the thickness value from the original fillet size.