Challenge

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

SSaravanakumar M K28 Jul 2022

Class A Surface:

The Class A surface is gives is shown in below image:

Procedure:

Step 1 : Connectivity of the Class A Surface

Check the connectivity of the Class A Surface that is to check that there is no gap between the components using the Join command or by visual inspection or also by using the Boundary Command.

Step 2 : Tooling Axis

The Tooling Axis is created using Bisecting Line Method.

Bisecting Line Method:

In Bisecting Line method is that the possiblities or clearance is checked along the direction using the intersection of surfaces along the axis on the plane of the Class A surface and the two lines is created on the intersections walls that is along the inclined walls of the intersections. Then the line is created by using bisecting line option in line command using the two lines and the point created and that line is Tooling axis.

For Creating tooling axis we create the point. The image of point is shown below

Then the intersection is created using XY plane using Axis System and point as reference. The below image shows the intersection

Then we create two line using line command along the inclined walls of the intersection.
Then a line is created by using two line and a point using Bisecting Line command. The image shows below is creating Intersection and Tooling Axis Along X Direction

Step 3 : Draft Analysis

Draft anlaysis is done based on the tooling axis. Draft analysis is used to check the Class A is maintained with minimum draft angle of 3 degree.
The Compass is used define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the surface. The image shows that draft analysis of the Class A surface with color scale variant.

Step 4 : Creating Class B Surface

We first Offse the Class A surface with 2.5 mm which is given as thickness.
Check for any discontinuity or gap between the joints or boundary is figured out in the offseted surface.
If any any then by using Multiplr extract, Multi Sections Surface, Sweep are used to fill the gap.
Thus the Class B surface is created. The image shown below is Class B Surface.

Step 5 : Creating Class C Surface

The Class C surface is the connection between Class A and Class B surface.
Then the boundary is extracted using Multiple Extract command or Boundary command.
Then these extracted surface is Swept using Sweep command with reference surface option is used.
Thus the Class C surface is created. The image shown below is Class B Surface.

Step 6 : Final trim to obtain Door Handle Plastic component

The last step is triming the Class c surface with the Class B surface.
Then the obtained surface is converted into solid using Close Surface and thus the final Door Trim Plastic Component is obtained. The image is shown below is Door Handle Plastic component

Step 7 : Rib Creation

Design rules for Rib:

Sketch For Rib:

We create a sketch by giving providing the plane asbase surface which is extracted using Multi Extract command and the point as Tooling Axis.
Then we create a line then we dimension the line with respect to axis.

Then we Extrude the line with height as 12.5 mm, as the rib design rule is Height = 5*wall thickness here the wall thickness is 2.5 mm, so Height = 2.5*5 = 12.5 mm.
Then Thickness is 1 mm, as the rib design rule is Thickness = 0.4*Wall Thickness here the wall thickness is 2.5 mm, so Thickness = 0.4*2.5 = 1 mm.
Then we gvie Draft using Draft command as 0.5 mm.
Then we gave Fillet value as 0.25 mm using Edge Fillet command.

Step 8 : Screw Boss Creation

Design rules for Screw Boss:

Draft - 0.5 degrees on the walls of boss
Thickness - Typically 40%* of the nominal wall at the base.
Height to Diameter Ratio - 3:1
Radii - 0.25mm maximum radii.

Sketch For Screw Boss:

We create a sketch by giving providing the plane asbase surface which is extracted using Multi Extract command and the point as Tooling Axis.
Then we create a circle then we dimension the circle with respect to axis.

Then we Pad the circle with height as 12.5 mm.
Then we gvie Draft using Draft command as 0.5 mm.
Then we gave Fillet value as 0.25 mm using Edge Fillet command.

Screenshots of the solid model:

Isometric:

Front View:

Side View:

Top View:

Draft Analysis of the Solid:

Draft analysis is used to check the solid component is maintained with minimum draft angle of 3 degree.
The Compass is used to define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the solid. The image shows that draft analysis of the solid with color scale variant.

Screenshots of the solid model with the proper color code of the draft angle in various orientations: