Week 9 - Attachment Feature Creation (Ribs & Screw Boss) - Challenge 1

    Attachment Feature Creation (Ribs & Screw Boss)

AIM:

• To Create the Door Handle Component from the given Class-A surface.
• To Create the tooling axis for the given Class-A Surface meeting the requirements of the draft angle.
• To Attach B side Features in the component.
• To perform the Draft analysis on the model. 

TOOLS USED:

• Boundary
• Join
• Multiple extract
• Bisecting line
• Trim
• Surface offset
• Draft analysis
• Intersect
• Surface sweep
• Close body surface

DESCRIPTION:

 CREATING TOOLING AXIS -

The Tooling Direction is basically the direction that the mold pulls a part. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dye line or the Tooling Direction.

Tooling Axis creation:

It is defined as the direction in which the mould/core and cavity open. Selection of the direction of the tooling axis depends on the ease at which components can be easily ejected.

By analysing the component the most easily ejectable direction is somewhere close to the Z direction,(might be inclined to it) so we have made a sketch on the YZ plane of Axis System) to create a bisecting line considering the 2 faces which might be difficult to be tooled.

One more sketch is created on the ZX plane of Axis System for considering the lone side face for tooling direction. In the sketch, a line is drawn with a suitable angle to the lone side face so that with the resultant tooling axis the side face is cleared.

Then resultant tooling axis is created using the bisecting method.

Class- A Surface:

• In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality.
• It is the visible aesthetic surface of any automotive component.
• Class A surface refers to those surfaces which are visible and abide to the physical meaning, in a product.
• This classification is primarily used in the automotive and increasingly in consumer goods industry.
• It is a requirement where aesthetics has a significant contribution.
• For this reason, the exterior of automobiles is deemed Class-A.

 PUBLICATION

• Publication is done to the component to make it visible and navigate easily.
• To publish the component go to tools > publications and then select the tooling axis and the class A surface.
• A separate tree structure is formed under the main part.

DRAFT ANALYSIS

                         The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

• Before going to drat analysis go to customized view parameter >under mesh >check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compasss to define the draft direction.
• In the colour scale change the draft angle to 3 degree.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.
• The draft analysis is complete.

CREATING CLASS B SURFACE:

• From the Class A surface , offset a set of Surface for to create the Class B surface by Using Extract Command From Below Image.
• We can use extract command for all surface we needed for to create Class B Surface and used multiple extract tool to get guide curves.
• Used multi-section surface tool for to fill up patches on the offseted surface.
• Extract the surfaces from the class A using multiple extract and untrim them.
• Use Extrapolate to make sure that all the untrims are properly intersected to trim and offset the surfaces to 2.5 mm to create the thickness.
• Trim the extra surfaces using trim command.
• Insert them into new geometrical set and name it with respective part names.
• Apply fillets to the model after creating the entire surface.
• If the edges are outside the fillet value will be added to the thickness of the component and if the edges are inside, the fillet value will be subtracted from the thickness of the component, for instance the thickness of the component Is 2.5mm the fillet value is 15mm so the outside portion value should be 17.5mm and inner eges should be filleted 12.5mm to get uniform thickness.
• Perform trims one at a time so that it will be clear to understand.

CREATING CLASS C SURFACE

• Extract the boundary from the class A surface using boundary command.
• Using disassemble tool to divide the boundary as the boundary contains domains.
• Use sweep command > choose profile type line > subtype as with draft direction > choose guide curve and draft direction > draft angle as 3 degree > preview.
• After getting sweep then trim the output with class B surface to get final output.
• Now open part design workbench and using close body surface create a solid of the component.

B SIDE FEATURES CREATION

        RIB CREATION

• Design Principle for Rib Creation

• Sketch Used For Rib Creation

• RIB

• SCREW BOSS DESIGN
• Design Principle for Screw Boss Creation

• Sketch Used For Screw Boss Creation

• SCREW BOSS

FINAL DRAFT ANALYSIS FOR PART MODEL:

• Finally the draft analysis has to be performed on the solid model that we get as a output and below image are attached. We achieved the requirement.
• The green colour area shows that it satisfies the 3 - degree draft angle.
• In below image the draft angle has been made for the output we had.

 3D MODEL

• ISOMETRIC VIEW

• FRONT VIEW

• SIDE VIEW

TREE ORDER:

CONCLUSION:

• The main tooling axis has been created successfully using the feature draft analysis tool.
• Final closed surface has been created by using the trim and join feature.
• The part body has been created by using closed surface tool.
• Draft analysis has been successfully done on the part body.
• Rib and Screw creation has been done.
• Thus the above challenge has been finished with the proper input and all the required documents are attached.