Challenge

Week 9 - Challenge 1 - Base Bracket Design

REPORT ON BASE BRACKET DESIGN

STEPS TAKEN TO CREATE THE BASE BRACKET DESIGN ARE AS FOLLOWS:-

WE WILL RECEIVE CLASS A SURFACE AS AN INPUT TO CREATE THE SOLID MODEL BY CREATING THE CLASS B AND CLASS C OUT OF THE CLASS A SURFACE AS SHOWN BELOW.

2. TOOLING AXIS-

INITIALLY WE WILL CREATE AN DUMMY AXIS BY LOOKING AT AN CLASS A SURFACE AS SHOWN BELOW.

AS THE TOOLING AXIS SHOULD CLEAR THE FACES AS IT MAY CONTAIN PARALLEL AND PERPENDICULAR FACES, THE PERPENDICULAR FACES CAN BE EASILY CLEARED BUT PARALLEL FACES ARE DIFFICULT TO CLEAR AS IT CREATES FRICTION BETWEEN MOULDED COMPONENT, CORE AND CAVITY CAUSING WEAR AND TEAR OF CORE AND CAVITY SURFACES AND REDUCES THE ASTHETIC PART OF MOULDED COMPONENTS.
TO CREATE THE TOOLING AXIS WE HAVE TO ANALYSIS THE BEST SUITABLE AXIS ALONG X,Y AND Z AXIS.
WE HAVE TO CLEAR THE HOLES PRESENT IN IT AND WE HAVE TO REDUCE THE COST BY ELEMINATING THE SIDE CORE IF POSSIBLE.
INTERSECT ON THE CLASS A SURFACE ALONG THE Y AXIS AS SHOWN IN BELOW FIGURE.THE YELLOW AXIS LINE INDICATES THE DUMMY TOOLING LINE.

CONSTRUCT THE LINES ALONG THE VERTICES AND BISECT THE LINE TO OBTAIN THE TOOLING AXIS OF CLASS A SURFACE.THE BLACK AXIS LINE INDICATES THE TOOLING AXIS OBTAINED FROM BISECTING THE LINES AS SHOWN BELOW.

3.DRAFT ANALYSIS:-

IT IS THE STUDY WHERE WE CHECK THE DRAFT ANGLES ON THE SURFACES.
USING FEATURE DRAFT ANALYSIS WE GET THE DRAFT ANGLES BASED ON THE COLOUR CODES.
COMPASS IS USED TO DEFINE THE CURRENT DRAFT DIRECTIONS.
ON SELECTING THE SURFACE IT TURNS INTO EITHER BLUE OR GREEN COLOUR AND IT SHOULD BE IN GREEN COLOURE OTHERWISE WE CAN FLIP THE TOOLING DIRECTIONS.THE GREEN COLOURED SURFACE INDICATES THAT IT CAN BE EASILY CLEARED WHILE MOULDING THE COMPONENT.

THE MINIMUN DRAFT ANGLE TO BE MAINTAINED IS 3 DEGREES AND IT CAN BE CHANGED TO 7 DEGREES FOR IP DESIGN TO ENHANCE ITS ASTHETIC PROPERTIES.
THE COLOUR CODE FOR FULL ANALYSIS MODE ARE AS GIVEN BELOW.

4.BASE BRACKET DESIGN:-

1.CLASS B SURFACES FORMATION-

HERE THE BASE SURFACE 1 IS CREATED WHICH IS THEN OFFSETED TO 2.5MM AND TRIMMED WITH BOTH RIB 1 AND RIB 2 AS SHOWN BELOW.
THE TREE STRUCTURE INDICATES THE OPERATIONS USED IN CREATING THE BASE SURFACE 1.

THE BASE SURFACE 2 IS CREATED AND OFFSETED AT 2.5 MM AND THEN TRIMMED WITH THE BASE SURFACE 1 TO OBTAIN THE CLASS B SURFACE.
THE TREE STRUCTURE INDICATES THE LIST OF OPERATIONS USED AS SHOWN IN BELOW FIGURE.

2.CLASS C SURFACE FORMATION-

TO CREATE THE CLASS C SURFACES THE BOUNDARY FROM THE CLASS A SURFACES IS FORMED AS SHOWN BELOW.

AS SHOWN IN BELOW TREE STRUCTURE CREATED THE BOUNDARY, USING SWEEP COMMAND FORM THE CLASS C SURFACE FOR THE HOLES.

JOIN ALL THE BOUNDARYS TO FORM A SINGLE CLASS C SURFACES AS SHOWN IN BELOW FIGURE.

ON TRIMMING THE CLASS B AND CLASS C SURFACES WE GET THE REQUIRED CLOSED SURFACE AS SHOWN IN BELOW FIGURE.

GO TO A PART WORKBENCH AND IN PART BODY DEFINE THE CLOSE SURFACE TO OBTAIN THE SOILD 3D MODEL AS SHOWN IN BELOW FIGURE.
THE TREE STRUCTURE INDICATES THE PUBLICATION OF TOOLING AXIS, CLASS A, CLASS B AND CLASS C SURFACES.

4.ORIENTATION VIEWS:-

Ship work like this
in your own course.