CHALLENGE REPORT

Week 9 Project 2

The class A doesn’t have any defect which needed to be improved. Hence this step has been skipped.

TOOLING AXIS:

Tooling axis has been created keeping in mind the position of the plastic feature. Hence, we need to create extracts and then proceed.

Thus, create 2 planes each perpendicular to the master section given here. Project 3d the edges of the feature in each of the master section.

Draw separate lines for each of the edges and use bisecting line for pair of lines in each of the master section. Again, use bisecting lines for the 2 bisecting lines.

Perform DA using the line we obtained.

SURFACE WORK:

CLASS B

To create a class B surface, we will be offsetting the class A for the given length of 2.5mm. There were some elements in the Class A which couldn’t be operated upon.

To solve that issue we have used sweep command with reference surface. The inputs were the guide curve and the profile. Join the offset and sweep.

Extrapolate the ends first and then extrapolate then the side walls for trimming purpose. The class B surface is complete.

CLASS C

First, work with the C surface creation of the side walls. Use the sweep command of the subtype “reference surface”. Use the class A surface as the reference.

For one of the side walls, create 2 boundaries as the surface has different slopes merging. Sweep them separately. Extrapolate them and trim them with each other.

Now create class C surface for the ends of the A pillar. Sweep the centre part of each end with draft direction with the tooling axis. Then sweep the side part of the drafted edge with reference edge.

Extrapolate the ends of all the sweeps and a trim and trim with each other.

Finally join class A and class C surfaces and trim the resultant surface with the class B. Go to part workbench and perform close surface command. Perform the draft analysis for the solid object.

FEATURE DESIGN:

Dog House:

First understand the master sections and visualise the shape of the dog house.

Extract the lines from the side profile and the limit, then extrapolate in both directions.

Measure the height of the dog house from the given drawings. Create a plane at that height and draw a line. Extrude all the lines in the direction perpendicular to the rear surface.

Now go to part design work bench and create a new body. Give it a thickness of 2.5mm.

Draw a separate line covering the front limit. Extrude the surface in the dimensions of the dog house. Split the dog house surface with it.

Now to create a groove at the bottom of the dog house we need to create a plane where the groove must cut. Carefully create a line not chopping off the whole dog house.

Offset the previously created surface for the dog house for a distance as per the design rules. Trim off both the surface and then use the split in the part design work bench.

Note: refer the drawings given by the supplier for more accurate dimensions.

Now perform the draft for the inner surface walls of the dog house for 0.5^o with respect to the lifter axis. Make sure the element is properly drafted and the material is being removed.

Rib Assembly:

Have a good look at the master sections given. Visualise how the ribs are to be assembled. We have a bottom rib and two ribs standing vertically on to it.

Measure the thickness of all the ribs using the measure tool. Create a new geometrical set for the ribs.

Draw a line on the bottom side of the rib using the master section. Make sure all the lines are isolated.

Note: all the geometries extracted from the master section should be isolated or else the master section might get affected.

Now extrude the line in the direction of the lifter axis. Make sure that the extrude stays well within the dog house starting limit.

Insert a new body and give the extrude a thickness of the given measurement from the master section.

Under the geometric set ribs, create new geometric set rib 1 and rib 2. Under the rib 1, create a straight line in between the two drafted lines of the master section.

Extrude that line to the given length. Make sure it crosses the bottom rib but not its first limit.

Go to part work bench and give extrude the given thickness. Give thickness on both the side of the equal magnitude.

Copy the body and paste it special using the result with link. Perform union trim of both the ribs with the bottom rib.

Similarly, union trim the obtained result with the dog house. Perform draft of 0.5^o to the necessary walls of the ribs. Make sure it clears the lifter axis.

Give the necessary edge fillets to all the edges inside and outside the dog house and the ribs.

Finally perform union trim the main part body with the obtain dog house body. Perform the final draft analysis of the body with 0.5^o.

To create a keyhole structure over the dog house roof, first analyse the given drawing.

Create a new plane where the sketch has to be drawn using parallel through point method. Create a new sketch of the profile.

Create a new body and pad the sketch such that, it does not cross the rib structure in the bottom.

Use the remove command with respect to the dog house to obtain the keyhole structure.

Draft the keyhole side walls with respect to the main tooling axis of 0.5^o. change the previous draft analysis and select the new object we created.

PLEASE FIND THE FOLLOWING FILES:

Part File: CATPart.zip

Images: Screenshots.zip

Report: CHALLENGE REPORT.docx