Week 9 - Challenge 1 - Base Bracket Design

Aim: To create a Base Bracket Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component.

Objectives: 

• Creation of Tooling Axis.
• Creation of Class B and Class C surface.
• Creating a solid part out of Surface modelling.
• Draft Analysis of Class A surface and final plastic component.

Tool Used: CATIA V5

Introduction: In this project we are designing a base bracket using given class A surface. The approach includes creation of Class B surface keeping 3 mm thickness in mind for the complete component. The design also included Class C creation from the given parent surface. 

Constraints:

• NO CHANGES IN CLASS A ARE ALLOWED.
• PART THICKNESS CANT DEVIATE BY MORE THAN $\pm$30%
• ALL DESIGN RULES SHOULD BE STRICTLY FOLLOWED.
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID.
• ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS.

CLASS A: Following surface is given as the input for the component creation.

CLASS A SURFACE

To continue with the design process first we need to find out the tooling axis for the surface and check for all the drafts using Draft Analysis tool of CATIA.

Draft Analysis for Surface A:

The analysis is done for 3degree draft. So as can be seen all the surfaces are more than 3deg. 

Creating of Tooling Axis: 

• Create an intersection of CLASS A surface with ZX plane and from the intersection create the tooling axis as shown below. 
• 
• Create a bisecting line using the lines shown above.
• 
• • Here, Line shown in dotted green is our tooling axis.

  Creation of Class B: 

  • Now for Class B creation, we have extracted surface from Class A and untrimmed them to obtain the original parent surface. 
  • These surfaces are then offset to the required thickness.
  • After offsetting, all the surfaces are trimmed into the required shape.
  • Required fillets are given to the surfaces.
  • 

  • Creation of Class C: 

    • For creating this surface we have extracted the boundry of Class A using multi-extract and then converted to smooth curve. 
    • Now this smooth curve is swept along the draft direction with a 3deg draft. 
    • 

    • Final Trims: 

      Class A + Class C:

      To make sure that there is not any open boundry between class A and class C, we have used join option to created the single body. This is done to make sure that the parting line doesn't lie between the these two surfaces.

    • 

    • Class A + Class B + Class C: 

      For this we have trimmed the above shown surface with the Class B surface using trim feature. 

    • 

    • All the main features are published as can be seen in the image shown above.

      Draft Analysis on the Final Component: 

      For this analysis, main tooling axis is taken draft reference. 

      Following results were obtained: 

    • 

SOLID MODEL

                                                        ISOMETRIC VIEW

                                                                   FRONT VIEW

                                                                        SIDE VIEW

                                                                      TOP VIEW