Week 9 - Challenge 1 - Base Bracket Design

BASE BRACKET DESIGN

AIM

To create the Base Bracket plastic component from the given Class A Surface as an input.

CLASS A SURFACE GIVEN AS INPUT

There are following steps, which have to perform by using Class A Surface:-

• First understanding the CLASS A SURFACE.
• Than creating the TOOLING AXIS.
• Draft analysis 1 for CLASS A SURFACE.
• Creating geometrical sets for CLASS B SURFACE.
• Creating CLASS C SURFACE using boundary and sweep command.
• FINAL TRIM to get Final Surface.
• Than go to PART DESIGN to get Close Surface Body.
• Draft analysis 2 for CLOSE SURFACE BODY.

1. First understanding the CLASS A SURFACE.

• Class A Surface is given as an input for product design.
• Class A Surface is thickened by using engineering features.
• The part which is obtaining after Class A Surface get thickened are use for manufacturing in real time application.
• The Boundary Condition of Class A Surface must be checked.

2. CREATING THE TOOLING AXIS

• From Class A Surface, we have to form TOOLING AXIS.
• The point where the component get molded from injection molding.
• On that point, create dummy axis first.
• Creating the intersection with Class A Surface by using plane.
• Also creating reference line ( LINE 1 AND LINE 2 ) along with tapper face.
• Bisecting these two line with reference point to create the TOOLING AXIS.

Creating the intersection with Class A Surface by using plane

Bisecting these two line with reference point to create the TOOLING AXIS

THE MAIN TOOLING AXIS DIRECTION FOR BASE BRACKET DESIGN IS:

3. DRAFT ANALYSIS 1 FOR CLASS A SURFACE

• Draft Analysis technique is used to analyse the product which we design is manufacturable and prevent the part being parallel to the direction of mold opening.
• The product can not be manufacturable, if it has 90° profile, which is parallel to the TOOLING AXIS.
• A small draft angle is applied in order to remove the component from the mold.
• No part is manufacture without the draft angle.

DRAFT ANALYSIS FOR CLASS A SURFACE

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

1. The green colour represent the draft angle is upto 3°.
2. The red colour represent the draft angle is 0°.
3. The blue colour represent the draft angle is in negative side.

4. Creating geometrical sets for CLASS B SURFACE

• THICKNESS 2.5 mm is given as input.
• The CLASS B SURFACE is obtained from CLASS A SURFACE on giving offset with thickness 2.5 mm.
• CLASS B SURFACE is created by using extract CLASS A SURFACES one by one (ribs,base surface), than untrim all extract surfaces, than extrapolate each of untrim surfaces, than trim all surfaces and get offset of that trim surfaces with thickness 2.5 mm.
• The offset value 2.5 mm should be ensured from each side or views.

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

THE OFFSET VALUE FOR FILLET SIZE :-

1. THICKNESS + RADIUS = OFFSET INSIDE THE CLASS A
2. THICKNESS - RADIUS = OFFSET OUTSIDE THE CLASS A

Here, the EDGE FILLET RADIUS value for given BASE BRACKET is 3 mm.

and THICKNESS = 2.5 MM

SO, The offset is inside the CLASS A SURFACE = 3 + 2.5=5.5 mm

Edge Fillet size of CLASS B SURFACE is 5.5 mm

5. CREATING CLASS C COMPONENT

• The CLASS C SURFACE is the final output obtained from the CLASS A and CLASS B Surface.
• Using boundary of CLASS A SURFACE and sweep the boundary with draft value 3°.
• The CLASS C SURFACE has the thickness 2.5 mm and draft value as per requirement provided.
• The CLASS A and CLASS C SURFACE are JOIN and TRIM with CLASS B SURFACE to form the final BASE BRACKET SURFACE.

CLASS A + CLASS B + CLASS C = FINAL PRODUCT WITHOUT TRIM

6. AFTER FINAL TRIM SO FINAL BASE BRACKET SURFACE OBTAINED

7. GO TO PART DESIGN TO GET CLOSE SURFACE BODY

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

8. DRAFT ANALYSIS 2 FOR BASE BRACKET FINAL CLOSE BODY

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

1. The green colour represent the draft angle is upto 3°.
2. The red colour represent the draft angle is 0°.
3. The blue colour represent the draft angle is in negative side.

TREE STRUCTURE OF INPUT (CLASS A SURFACE)

TREE STRUCTURE OF BASE BRACKET CLASS B SURFACE

A. RIB TREE STRUCTURE

B. BASE AND FILLET TREE STRUCTURE

TREE STRUCTURE OF BASE BRACKET CLASS C SURFACE

TREE STRUCTURE OF BASE BRACKET CLOSE BODY SURFACE AND DRAFT ANALYSIS