Week 9 - Challenge 1 - Base Bracket Design

CHALLENGE 10 BASE BRACKET DESIGN

AIM- Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

INTRODUCTION-

CLASS A SURFACE – The outermost skin of a part model which is visibly aesthetic surface/ free-form surface having an optimal shape & high surface quality. Design engineer with help of class A Surface create class B surface & class C surface.

CLASS B SURFACE- A surface below the Class A surface is created by design engineer to give a desirable thickness. This surface is also known as engineering surface.

CLASS C SURFACE- A surface that join Class A Surface & Class B surface.

METHODOLOGY

1) TOOLING AXIS

2) DRAFT ANALYSIS

3) CLASS B SURFACE

4) CLASS C SURFACE

5) CLOSED SURFACE (SOLID MODEL)

1) TOOLING AXIS

· First, we check all the three directions in X, Y, Z & check for suitable for the tooling axis. This case, Z Direction is the suitable tooling axis to create.

· Create a point by using circle/ellipse. Then generate a line point-direction to Z-Direction.

· Generate dummy tooling axis line by point-point direction.

· Intersect the YZ plane of the axis system by intersection command. Intersection line is generated.

· Create a bisecting line with help of dummy tooling axis line & select the point. A final tooling axis is generated.

1) DRAFT ANALYSIS

· Go to insert <analysis < feature draft analysis.

· Align the compass with the tooling axis.

· Click on the surface & see the surface within the permissible limit of the draft values.

· The surface should be green & in the column proper value (3deg) should be inserted.

1) CLASS B SURFACE

(i) RIB 1 & RIB 2

· Extract the rib surface for rib 1 & rib 2 respectively.

· Use un-trim command to un-trim the surface.

· Extrapolate one surface at a time.

· Trim the surface to create desired shape.

· Offset it down by 2.5 mm thickness.

(i) BASE SURFACE

· Extract the slant surface & flat surface simultaneously.

· Un-trim the surface one at a time respectively (for both surface).

· Extrapolate the surface one at a time respectively (for both surface)

· Trim the surface to create the desired B Surface.

· Offset downward direction by 2.5 mm thickness.

1) C SURFACE

· Extract the boundary from the boundary command from Class A surface.

· Use sweep command on the boundary at angle of positive 3 degree. It will generate the C Surface.

· Extract the boundary of the holes on the Class A Surface, then use sweep command to generate the C surface in the holes.

· At last, join the Class A Surface & C Surface together by join command.

· Unhide the B Surface. Trim the B Surface & C Surface.

1) CLOSED SURFACE (SOLID MODEL)

· Go to mechanical design, define the part body tree.

· Use the command closed surface & select the last trim section.

· Converted to solid model.

TREE FEATURES

DRAFT ANALYSIS

CLOSED SURFACE

PUBLICATION

CONCLUSION- All instruction has been followed to create the base bracket accordingly.