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

ANS 1

TOOLING AXIS = It is the axis or direction along which the core and cavity move and the required part ejected along this direction. In this question, we are going to explain making tooling axis by NORMAL TO SURFACE method.

STEP 1 =Selecting the surface along which we need to create the tooling axis.

STEP 2 = Creation of point using the point tool using the option on the surface. select the extracted surface and give 0mm in the distance option to create the point in the middle of the surface.

STEP 3 = Creation of the required tooling axis using the line tool and selecting the normal to surface option to give extracted surface in the reference surface option and the previously created point in the reference point option and obtain the required tooling axis.

DRAFT ANALYSIS = It gives us information about the parts which tells us which part clears the mold walls easily so as to minimize the machining process in the finished product and final product ejected easily and minimize the contact between the product and mold walls.

STEP 1 = Select the Feature draft analysis tool and move the compass to the tooling direction and align the compass w axis to the tooling axis. After aligning the compass with the tooling direction again click the compass tool to insure the proper alignment of the w-axis with the tooling axis. After the proper alignment uses the locking tool to lock the compass with the tooling axis.

STEP 2 = Click anywhere on the A surface to generate the draft analysis report and use the quick analysis mode option to see the color code values where the green color defines the parts which have a draft angle greater than the green color code value generally it is up to 3 degrees in values. The red color gives information about the parts which have angles between 0 to up to a green color value which is generally up to degrees. The blue color gives information about parts that have an angle less than the red color. If A surface comes out in green color means our tooling axis is perfect and we are ready to go for the formation of B and C surfaces.

NOTE: some surface of the class A body does not clear the draft analysis test along the tooling direction as the designer does not give enough draft angle to the surface. We go with this surface as we are not allowed to modify the surface.

RIBS = Ribs are the support or the strength-providing elements without increasing the thickness of the given product. It gives sufficient strength without increasing the thickness and cost of the production of the components.

The image above gives us the empirical relationship between the component thickness and height, draft angle, and fillets for the ribs creation.

SCREW BOSS = Screw boss is the component formed on the surface for the easy joining of the two components. It also serves as an alignment tool when we join the two components for the proper seating of the product.

• 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.

The image above gives us the empirical relationship between the component thickness and height, draft angle, and fillets for the screw boss creation.

NOTE = While forming the C class surface two outer edge does not clear the draft analysis test because when we go with the draft angle with reference to the surface require a very large angle and if we go with the reference with the tooling direction makes the outer surface pointy edge and makes it difficult for the final trim of the door handle.