Week 9 - Challenge 1 - Base Bracket Design

Aim :

create the base bracket plastic component through the given class A surface and perform the draft analysis of the model

thickness of the plastic part -2.5 mm

objectives:

1. create a tooling axis
2. generate class B and class C surfaces from the class A surface
3. convert the surface in to a solid body
4. use publication option to publish

• tooling axis
• class A, B and C surfaces
• draft analysis of class A and final surface

introduction :

this project involves creating a base bracket part from a class A surface . steps include crating a class B surface with a 2.5 mm thickness and class C surface derived from the class A surface

class A surface :

the class A surface is primary reference surface in vehicle design , used to create the Class B surface

tooling AXIS :

the tooling axis defines the direction used in the manufacturing process to create components with a positive draft angle , ensuring the component meets design requirements

creation of the tooling axis:

in this project , the tooling axis is created using the bisecting method :

1. create a point at the centre of the hole or where the surface of the class A interests
2. create a plane passing through the point , perpendicular to the class A surface
3. extract the edge of the class A surface on the plane using intersection method
4. create line passing through the inclined surfaces
5. the bisection lines represents the tooling direction of the component , which is known as the tooling axis . it indicates the direction of the tool used in the components manufacturing process

class B surface :

the class B surface , also called the engineering surface , is created from the class A surface with the component thickness

creation of the class B surface :

class B surface is generated by extracting the class A surface and offsetting it by the component thickness (2.5 mm) . its includes rib1, rib 2 and base surface from class A

steps to create class B surface :

1. extract flat surfaces such as the top ribs , inclined surfaces and the base surfaces from class A
2. untrim the surfaces separately
3. extrapolate the edges using the point continuity until they interest
4. trim the surfaces as in the untrimmed class A surface
5. offset the trimmed surface by the component thickness (2.5 mm)
6. create edge fillets based on the class A surfaces

• for the external fillets , use fillet radius + thickness
• for the internal fillets , use fillet radius -thickness

the result is trimmed and filleted as B surface

Class C Surface:

The Class C surface connects the Class A and Class B surfaces.

Creation of Class C Surface:

Class C surface is created by:

1. Extracting the edges and holes from the Class A surface.
2. Sweeping the extracted edges and holes along the Tooling Axis, applying a 3-degree draft angle towards the Class B surface.

Together, these surfaces form the Class C surface.

Final Trim:

Combine the Class A and Class C surfaces using the Join command.

Trim the Class A and Class C surfaces with the Class B surface to obtain the final surface of the component.

Switch to the Part workbench and use the Closed Surface tool to convert the closed surface of the component into a solid part.

tree structure :