Week 9 - Attachment Feature Creation - Challenge 2
Q) Creation of Door Trim with Dog house
1) Design Check - This includes the checking the given Class A surface for any gaps at the boundaries. There should be no gaps between the surface boundaries.
(i) Given Class A Surface
To perform design check operation, select boundary command and click on the given Class A surface.
Open surface edges are highlighted in green color, as observed from the figure, there are no surface gaps between boundaries. Therefore, this Class A Surface can be used for further operations of creating tooling direction, Class A , B and Solid body.
2) Creation of Tooling Direction
For tooling axis creation, all the axes directions i.e., x,y and z directions are to be checked for easy removal of the mould and low tooling costs.
(i) Feasibililty Check in all directions
X direction
Z direction
Y direction
Among all the directions, Y direction is the most preferable as there exists a bin region which is perpendicular to the Y axis.
(ii) Creation of Tooling Axis by Bisecting Method
To create a tooling direction, bisecting lines are created using the faces that are closely parallel or at positive draft angles to Z direction. Bisecting lines are created by intersecting YZ (X direction)and XY (Z direction) planes on the Class A Surface. A final bisecting line is created using already generated bisecting lines along their respective planes. This final bisecting line is the Tooling direction.
(a) X direction
The face that is perpendicular to Y direction can be easily cleared, the faces that are closely parallel to Y direction are at a positve draft angle are considered to create a bisecting line. A sketch of YZ plane is considered and is intersected with Class A Surface. A bisecting line generated using the faces that are at a positive draft angle w.r.t Y.
(b) Z direction
The face that is perpendicular to Y direction can be easily cleared, the faces that are closely parallel to Y direction are at a positve draft angle are considered to create a bisecting line. A sketch of XY plane is considered and is intersected with Class A Surface. A bisecting line generated using the faces that are at a positive draft angle w.r.t Y.
(c)Tooling Direction
The tooling direction is obtained by bisecting the above two bisecting lines.
3) Draft analysis
Draft analysis is performed on Class A surface to obtain the Main Tooling Axis. Materials option in customize view should be active before performing Draft analysis. Click on Draft analysis, a color code variant dialog box appears displaying colors, green for positive draft angle, the nominal draft angle for industrial applications is 3 deg. Therefore, 3 deg is provided, the red color indicates a draft angle between 3 and 0. The blue color indicates a negative draft angle.Click on the the compass option on the dialog box , click on the compass and drag it and align it onto the bisector, now click at any point on the surface. The entire surface on topside appears green, this indicates that all the faces can be cleared easily and the bisector created can be considered as the Main tooling axis.
Draft Analysis on CLASS A SURFACE
The above image shows the DRAFT ANALYSIS ON CLASS A SURFACE with color code variant. Green color indicates clearance of all faces with draft angle of 3deg.
4) Dog House creation
Design rules for Dog House
Thickness T of solid = 2.5mm
C = 0.4T = 0.4x2.5 = 1mm
B = between 3 to 6mm
The above image shows the Dog House with draft angle 1.5deg on outer faces, 0.5deg on inner faces, fillet 3mm on outer edges and 1mm on inner edges
DRAFT ANALYSIS ON FINAL PLASTIC SOLID BODY with DOG HOUSE
The Draft analysis on Solid Body with color code variant can be observed from the above figure. It can be observed from the figure that all faces that are green in color are cleared with a draft angle of 3 deg. The red color indicates a draft angle between 0 and 3 deg.
Views of final plastic component
Isometric view
Front view
Top view
Left view
Right view
