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

Tooling Axis:

To create the tooling axis, I extracted the surface of class A with no propagation and I created the point at the centre of the extracted surface and created a line at that point in the Y direction.

Class B surface Creation:

To create the class B surface for the door handle, I offset the class A surface to 2.5mm inside. Once the class A surface is offset created, according to the thickness, we can observe some patches on the offset surface due to the fillets on the class A surface. Now, we need to close those patches. I used multi-section solid command to close the patches.

Class C Surface creation:

I used the sweep command in the geometric shape design workbench to create the class C surface.
Initially, I extracted the edges of the class A surface with tangent continuity by using the multiple extract command. After extracting the class A surface edges correctly, I sweeped the extracted edges with 93deg toward the class B surface. After sweeping the extracted class A surface edges, I extrapolated the edges of the sweep for 6mm to intersect the sweep edges with each other. Now I trimmed the extrapolated surfaces together to create a complete sweep surface towards the class B surface. I joined both the trimmed sweep surface and class A surface together, to get the class A+C surfaces as a single surface. Now, to create a solid body for the door handle we need a closed surface. I trim the class B surface with joined class A+C surface to make the closed surface of a door handle.

RIB Design:

To create the ribs on the solid part body, we need to follow the above-mentioned design guidelines. Initially, I create a line sketch for the rib and I extruded it in the tooling axis direction and I thicken the extruded surface to 1mm toward the inside,
after thickening the extruded surface I gave 0.5deg of draft angle to the rib, and I union trim the rib with the part body to remove the extra surface of the rib, by union trimming the rib with the part body the rib gets added to the main part body without the unwanted extra part. After adding the rib to the part body, I gave the fillet to the rib with a radius of 0.25mm (as per the design parameters 0.25mm is the maximum fillet radius). In the same way, I created the rib-2.

SCREW BOSS Design:

To create the screw boss, I created the circular sketch in the sketcher workbench and I padded the sketch to 12.5mm. Now, I drafted the inside and outside surfaces with 0.5deg in the tooling axis direction. After creating the screw boss, I gave 0.25mm of the fillet to all sides. Now, I translated the screw boss toward the right side for 35mm. To keep the screw boss stiff and rigid, I created 4 supporting ribs for each screw boss.