Create Engineering Features for the Centre Console Coin Holder

AIM : Create the boss and dog house for the centre console coin holder considering the design rule.

OBJECTIVE :

1. Create tooling axis and perform draft analysis on class-A surface.
2. Create Class-B and Class-C surface, make close surface.
3. Create a Rib, Boss, and Dog House consider the design rule.

DRAFT ANALYSIS :

• When creating Plastic component in core and cavity it is very difficult to eject part from tool of an angle of 90 degree. A small draft angle provide to each area of the part in order to easy removal of the component from the tool.

SCREW BOSS :

• A boss feature finds use in many part designs as a point of attachment and assembly.
• The most common variety consists of cylindrical projections with holes designed to receive screws, threaded inserts, or other types of fastening hardware.
• Under service conditions, bosses are often subjected to loadings not encountered in other sections of a component.
• Provide a generous radius at the base of the boss for strength and ample draft for easy part removal from the mold.

DOG HOUSE :

• Dog house is an engineering feature used in plastic trim design.
• Dog houses are used as supporting feature. Sometimes other engineering features like snaps, locators etc. are mounded on them to increase their strength.
• Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from mould cavity.
• Dog house and other engineering components are built on B-surface.

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.

GENERAL GUIDELINE FOR DOG HOUSE :

• 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

PROCEDURE :

STEP 1 : TOOLING AXIS CREATION

• To perform a Draft analysis the tooling cration is very mandatory. To create a tooling axis analize the best direction for it. In this perticular component the Y-direction is very convenient to create the tooling axis.

STEP 2 : DRAFT ANALYSIS ON CLASS-A SURFACE

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction. And move curser to part and select point and it shows the green color which represent the draft angle is 3 or above.

STEP 3 : CLASS-B SURFACE CREATION

• From given Class-A surface create a Class-B surface of an offset of 2.5 mm as a given thickness.
• To create a Class-B surface we have to extact all the wall and then untrim it.
• After untrim the walls extrapolate then at 30 mm distance to perform further operation on it.
• Then provide an offset of 2.5 mm to untrim walls.
• Then trim the walls to get an desired shape for the component.
• Then use the Fillet to edges of internal wall.

STEP 4 : CLASS-C SURFACE CREATION

• To join Class-A and Class-B surfaces we have to create a Class-C surface.
• To create a Class-C surface we have to extact the boundries of the Class-A surface.
• After that use the sweep command to sweep the boundries along with tooling axis as an second guide curve.
• There will some minor gap between Class-a and Class-C surface due to draft angle.
• To overcome this problem extrapolate the class-A and Class-C surface and trim it.
• After that join the Class-A and Class-C surface using the join command.

STEP 5 : CLOSE SURFACE CREATION

• To create complete close surface trim the Join of Class-A nad Class-C from the Class-B surface to get desired close surface.
• After that go to Part Workbench use Close Surface command to get thicken part.

STEP 6 : DRAFT ANALYSIS ON CLOSE SURFACE

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction. And move curser to part and select point and it shows the green color which represent the draft angle is 3 or above.

STEP 7 : CREATE RIBS ON COIN HOLDER

• Create ribs on coin holder to provide more strength using surface and thicken command.

STEP 8 : DRAFT ANALYSIS OF RIBS

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction. And move curser to part and select point and it shows the green color which represent the draft angle is 3 or above.

STEP 9 :

A) CREATE SCREW BOSS

draw circle and extrude it.

Then create rib to provide extra strength to the screw boss and plastic component.

B) DOG HOUSE

Draw sketch to create dog house and using sweep command sweep the profile

Swept surface defination-Profile type-Line-Subtype-With Draft Direction

Provide 1.5 draft angle.

STEP 10 : DRAFT ANALYSIS OF THE COMPONENT

• To perform Draft Analysis go Insert-Analysis-Feature Draft Analysis.
• Then the Draft analysis Tool Bar is opend, select the Switch Bezel where we perform the draft analysis.
• Then set compass to the tooling axis by using Uses the Compass To Define the New Current Draft Direction.
• Then the lock the compass using Locks and Unlocks the draft direction.

ISOMETRIC VIEW

FRONT VIEW

BACK SIDE VIEW

LEFT HAND SIDE VIEW

RIGHT HAND VIEW

TOP SIDE VIEW

BOTTOM SIDE VIEW

TREE STRUCTURE

FILE:

https://drive.google.com/file/d/1t2o_RBH4pbV_h0asbNWXUs3bK7bnOarW/view?usp=sharing