Week 9 - Challenge 1 - Base Bracket Design

Base Bracket Design

AIM :

To create the Base Bracket Plastic component through the given Class-A surface.

OBJECTIVE :

• To make sure that the model meets the requirements of the draft angle.
• To create the Tooling axis using bisecting method.
• To perform Draft analysis on the given Class A Surface.
• To create the required Class B and Class C surfaces.
• To obtain a solid body from the surface using Close Surface feature.

CLASS A SURFACE :

• Class A surfaces are those surfaces which are curvature continuous while providing the simplest mathematical representation needed for the desired shape and does not have any undesirable waviness.
• The Class A surface is the used to begin the design of a product.
• All the further intricacies of the component are created based on the Class A surface.

CLASS B SURFACE :

• The Class B surface is created from the Class A surface , keeping the thickness of the component in check.
• The Class B surface resembles an offsetted surface from the Class A.

CLASS C SURFACE :

• The Class C surface is used to bind the Class A and Class B surface together inorder to form a closed surface.

Creating Tooling Axis

• Initially the given Class-A surface was imported and checked for any discrepencies in the boundary.
• A dummy Tooling axis was created using a reference point created on a hole of the given surface.
• The lines which might cause trouble during the operation were identified and a reference line was created for each of the identified lines.
• Finally a Tooling axis was created from these two reference lines using Bisecting option.

Draft Analysis & Draft angle in various orientations (Isometric, Front, Side, and Top View)

• The Drafting analysis was performed using the Feature Draft Analysis command.
• Using this command the compass was set on the main tooling axis and the Draft angle was changed to 3 degree.

Class-A surface

Draft analysis Final

BASE BRACKET DESIGN PROCEDURE

CLASS-B SURFACE

RIB CREATION

1. Bringing in the class-A surface.
2. Extracting the rib surface.
3. Un-trim the extracted surface.
4. Extrapolate the un-trimmed surface.
5. Trim the surface as per required shape.
6. Repeat step 2, 3 and 4 for the next rib surface.
7. Offset the created rib surfaces for 2.5mm. ( CLASS-B SURFACE)

MIDDLE FLAT RIBS CONNECTING SURFACE

8. Extract the middle flat connecting surface from class-A.
9. Un-trim the extracted surface.
10. Extrapolate the un-trimmed surface.
11. Offset the extrapolated untrimmed surface for 2.5mm.
12. Trim the surfaces. (CLASS-B SURFACE)

CREATION OF BASE SURFACE

13. Extract the base surface from class-A surface.
14. Un-trim the base surface.
15. Extrapolate the base surface.
16. Offset he base surface for 2.5mm
17. Trim the base surface from the middle surface which is already created.

JOIN

18. Join all the class-B surfaces to make as one unit.

FILLET

19. Since the class-B surface is 2.5mm downwards to the class-A surface need to add this offset distance with the filleting radius observed from the class-A surface.

CLASS-C SURFACE

• The Class C surface connects the Class A and Class B surface.
• Initially the outline of the Class A surface was obtained using the Boundary command.
• The the Sweep command was used along With draft direction, with a draft angle of 3 degree.

This the connecting surface of class-A and class-B surface Create the boundary of class-A surface using boundary command

Use sweep command to generate class-C surface along the draft direction with 3 degrees drafting angle with respect to the tooling axis.

Extrapolate the hole features from class-A surface and trim them.

CLOSED SURFACE

Publish class-A, class-B, class-C surfaces and tooling axis.

Join all the surface together.

Create closed surface.

Tree Structure

(Isometric, Front, Side, and Top View)

CONCLUSION :

• The creation of Tooling axis and Draft analysis were performed.
• The solid component was created from the surface geometry.
• The necessary screenshots and files were attached.