Week 9 - Challenge 1 - Base Bracket Design
CREATION OF TOOLING AXIS:
1. Need to analyse the class A Surface in all three directions and decide which direction allows easy clearance of all structures of the class A.
2. In the given A surface, in the X direction, the holes cannot be cleared.
3. Similarly in the Y direction, the ribs cannot be cleared.
4. But in the Z direction, the ribs and the holes can easily be cleared. So the tooling direction is the Z direction.
5. Create a "Dummy Tooling Axis". This can be done by creating a line in the Z direction at at point on the surface.
6. Now take intersect of the surface with the YZ plane and obtain an intersect.
7. Do a visual inspection of the intersect and see which faces can be cleared directly. Any faces that seem to be parallel to the dummy tooling axis are the ones that are tricky to clear.
8. Now construct lines at the edges which are tricky to clear by using two point line method and extend them well. Bisect the two lines which are corresponding on either side of the dummy tooling axis and create an extended line. This is the line that will be used as the Tooling Axis of the given surface in this case.
DRAFT ANALYSIS OF THE CLASS A SURFACE:
1. Change the shading view of the class A into material mode.
2. Then select Compass to give direction of the draft. This direction should be the same as tooling direction.
3. Drag the compass and place it in tooling direction. Lock the draft direction using the lock tool and then click on the surface with the x. Then the colour assigned by the draft analysis will be reflected on the surface.
4. In this case as the compass is getting adjusted in the direction opposite to the tooling direction, we can simply flip the direction by using the tool that inverses draft direction.
5. Once this is done, obtain the colour variant scale and give green colour for an angle over 3 degrees and red colour for an angle between 0 and 3 degrees. Then give blue colour for an angle below 0 degrees which are negative angles.
6. The whole top of the class A surface is in green colour which means the class A surface satisfies the draft requirements.
DRAFT ANALYSIS OF THE PLASTIC COMPONENT:
1. Change the shading vieew of the plasstic component into material mode.
2. Then place the compass on the tooling axis in order to align it towards draft direction. Lock the draft direction and with the x mark, click on the plastic component.
3. The entire component will change colour based on the angle of the draft at that face.
4. In this case as the compass is getting adjusted in the direction opposite to the tooling direction, we can simply flip the direction by using the tool that inverses draft direction.
5. Once this is done, obtain the colour variant scale and give green colour for an angle over 3 degrees and red colour for an angle between 0 and 3 degrees. Then give blue colour for an angle below 0 degrees which are negative angles.
6. We can see some faces that do not have a draft of more than 3 degrees. Try measuring the draft angle on such faces by using "Analyses over running point" option.
7. If the draft angle is above 2.9 degrees but under 3 degrees, in such cases, decrease the draft limit to 2.9 degrees.
8. Still some faces do not have required draft angle. Now we need to increase the angle of the sweep from 3 degrees. This needs to be done in a co-ordinated way by checking the draft analysis to see if the sweep angle is enough to obtain required draft angle on the required faces.
9. Once all the faces on the top surface of the part are green, it means all faces have required minimum draft.
IMAGES OF THE COMPLETE DRAFT ANALYSIS OF CLASS A SURFACE:
IMAGES OF THE COMPLETE DRAFT ANALYSIS OF PART BODY:
IMAGES OF THE COLOUR SCALE VARIANT OF CLASS A SURFACE:
IMAGES OF THE COLOUR SCALE VARIANT OF THE PART BODY:
IMAGES OF PART MODEL WITH PROPER COLOUR CODE OF DRAFT ANGLE IN VARIOUS ORIENTATIONS:
ISOMETRIC VIEW:
FRONT VIEW:
SIDE VIEW:
TOP VIEW:
