Challenge Report.

Week 9 challenge 1

Rib making

Ribs are made on the surface which might face wrappage or is feeble to loads. They are formed on the B side of the surface.

Create a new geometric set naming “rib design”. Extract the surface on which the ribs are to be formed. Draw a sketch (line) on which the rib is constructed. Change its line-weight.

The rib we manufacture should follow the tooling direction. Extrude the line along the tooling direction for 5*t (t=thickness of the component wall). Extend the bottom limit to 1mm so that there is no gap in the component and the rib.

Go to Part Design workbench and insert a body. Thicken the surface to maximum of 0.4*t. Thicken it to 0.4*2.5mm.

Go to draft cmd. and select the lateral faces of the rib. Neutral element = base of the rib; Pulling direction = tooling axis. Draft angle = 0.5^o (each side). Check the top that edge length < 0.75mm.

Assemble the rib body to the main part-body. Add fillets to the faces of the rib 0.25mm.

Checking the rib-root thickness:

Take a section of the component with the rib from the middle. To do that, create a plane passing through the end point of the tooling axis, in x-y plane. Go to generative sheet metal workbench and create an intersection.

Select the first element: whole part-body of the component and second element: the plane we created.

Create a circle in the centre of the wall below the rib. To create it, select the circle mode in “tri-tangent”.

Element 1: right click > create extract > select the fillet 1.

Element 1: right click > create extract > select the fillet 2.

Element 1: right click > create extract > select the bottom edge.

All the extracts must be in “no propagation”.

Measure the diameter of the obtained circle. D ~ 1.343mm. Check the “keep measure” box. Similarly measure the wall thickness.

Design of Screw Boss:

Insert a new geometric set “Screw boss design”. Use the existing extract of the face as the reference for the new sketch.

[We will be designing an M6 screw boss]

Draw 2 concentric circles of inner dia. being 5.2mm and outer dia. of 5.2mm + 0.6*thickness of wall, on both sides. i.e., 5.2 + 3mm.

Insert a new body and name it “screw boss”. Pad the sketch for 12mm high and 1mm deep. Draft the outer face for 0.5^o keeping the neutral element as the base extract and pulling direction as the tooling axis. Assemble the body on to the main part-body.

We should create ribs in order to support the boss. Copy-paste the existing sketch into the current geo. set. Make the circles ref. elements. Draw 2 ortho. lines diametrical to the circles. Constrain them using formula.

Insert a new body and give thick pad profile to the lines for 10mm high and 1mm thick and 1mm deep. A gap must be maintained to accommodate the screw features.

Now give draft to all the lateral faces for 0.5^o with base extract as the neutral element and pulling direction as tooling axis.

Now go to the body “Screw Boss” and define in work object Go to the current body and perform union trim with the screw boss and select the upper face to remove.

Assemble the new body to the main part-body. Apply fillets to the final object

Checking the screw boss root thickness:

Using the existing intersect, move the plane to the centre of the circles by “parallel through point”.

Create a new sketch with projection point at the bottom end of the tooling axis. Do intersect of the sketch workbench (in the project command.) and select the part-body.

Select the lines with the contour of the screw boss and fix it. Hide the fixes in the constraints. Note that here the sketch is not as expected it to be. This is due the section that we created.

To resolve this issue, make a copy of only the screw boss body that we just designed. We’ll use copying by link, into the main part design (right click > paste special > as result with link).

Translate the copied element such that it falls inside the extracted bottom face. Assemble it into the main part-body. Apply the necessary fillets.

PLEASE FIND THE FOLLOWING FILES:

-> Part file = CATPart.zip

-> Screenshots = Screenshots.zip

-> Report = Challenge Report.docx