Week 9 - Challenge 1 - Base Bracket Design

Work on writing a detailed report based on the Draft analysis result and add the images required

Detailed Report

First of all, we have to check the continuity of the given class A surface to ensure class A surface is properly joined or that no discontinuity is present. This can be done using the join or boundary command in CATIA. By looking visually in the below image we see that the surface has a continuous connected boundary as highlighted by the green line.

1. Checking continuity of given class A surface:

2. Toolimg Axis Direction:

The next step is to decide the tooling axis direction. The tooling axis is the direction in which the mold or core & cavity open. Analyzing the model visually to see which direction is most suitable for the tooling axis. From the below image, it is clearly seen that the surface has a hole at its top & cutout at the sides.

• From the X direction as the tooling axis, as shown below image, we require a side core for the top hole which increases mold cost.

• From the Y direction as the tooling axis as shown below image we require a side core for the top hole which is also not required.

• So Z direction as the tooling axis we clear this hole in tooling & this is the dummy tooling axis as shown in the below image.

• Now we will use the bisecting method to find the real tooling axis.
• Insert axis system. Take the intersection of the ZX plane with the class A surface. We will get the two curves.
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• Now we have to see which surface will create problems or will be difficult for tooling. Because the surface which is 90° to the tolling axis will be cleared. So we have to check the surface which lies parallel to the tooling axis direction. Make lines along parallel surfaces using point-to-point direction. Here we get two lines, now we will bisect the two lines & choose a vertical direction. This will be our tooling axis for X – the direction.

• Similarly we intersect the YZ plane of the axis system with the class A surface & repeat the same procedure again.

• Now we have two axis i.e. Tooling clearing the X-axis & tooling clearing the Y-axis. We will bisect this two axis to get our final tooling axis.

Draft Analysis:

• 1) To perform draft analysis. Go to insert < Analysis< Feature draft analysis.
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2) Before that switch the customize view parameter mode to material.

3) Click on the compass icon & align it with the tooling axis & click on the surface, we will get our results.

• From the above image, it is seen that the surface in green colour has more than 3° draft which is most required for tooling feasibility.

By inversing the draft direction, we get the below image.

We also check the draft angle of the running point on the surface.