Week 8 - Challenge 3 - Coin Holder Design

AIM

Create the Coin Holder Plastic component through the given Class-A surface.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. the Thickness of the component to be 2.5 mm

REPORT

CLASS A SURFACE

In automotive design, a class A surface is any of a set of free form surfaces of high efficiency and quality.  It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.

We have been given the Class-A surface and the first thing to do is to make sure that the given surface has no gap in between them. We can check it visually and also with help of Join or boundary commands.

The given surface has one boundaries which are one outer boundary. So, there are no other gaps found.

TOOLING AXIS

 The direction in which the mold or core and cavity opens is the tooling axis.

Dummy tooling axis

By checking the all three axis the best tooling direction is determined.

there is bin shaped area and wall around it .it is a major consideration for dummy tooling axis.the walls are almost 90 degree to surface. so the tolling axis should be perpendicular to flat base of bin area

created point on extracted base surface and a perpendicular line is drawn and Dummy tooling axis created

 

TOOLING AXIS USING BISECTING METHOD

Tooling axis for the part is created by using the dummy tooling axis using the bisectiong method .In order to check whether the  part is toolable in the direction,the class A surface is analysed and  the walls which are doubtful of clearing the 3 degree draft angle to the dummy tooling axis is identified.

an axis system is created on point to take intersection

first intersection is taken on yz axis

lines are drawn atthe walls which are almost parallel to dummy tooling axis

bisecting lineis drawn to this two lines

  

second intersection is taken along xy axis

lines are drawn atthe walls which are almost parallel to dummy tooling axis

bisecting lineis drawn to this two lines

TOOLING AXIS is created by bisecting the axis created on two intersections which is same as dummy tooling axis

 

DRAFT ANGLE

When developing parts for plastic injection molding, applying a draft (or a taper) to the faces of the part is critical to improving the moldability of your part. Without it, parts run the risk of poor cosmetic finishes and may bend, break, or warp due to molding stresses caused by plastic cooling. Equally important, an absence of draft may prevent parts from ejecting from the mold, damaging not only the parts but possibly the mold itself—a costly and time-consuming detour.

DRAFT ANALYSIS OF CLASS A SURFACE

Change the view to material mode for draft anlysis

draft analysis is done using featured draft analysis tool

Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar

the surface is showing green colour so that the surface clears the minimum draft angle of 3 degree

By using the analyses under the running pointwe can check  draft angle  on the individual faces. It shows how much draft on specific points when we move the cursor point.

Green colour - above 3 degree positive draft

Red colour -between 3 and 0

orange colour- below 0 degree

CLASS B SURFACE

CLASS B SURFACE

Class-B surface means the thickness of a part it is not visible and is inside part. In other words, the Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.The Class B finish is a quality finish with only minimal imperfections. A Class B finish is the most common finish for exterior surfaces. It is normally specified on surfaces such as external covers, panels, and parts that are fairly prominent.

BASE

extracted the surface

untrim the surface

Extrapolate the surface

Trim the  surface

offset to the thickness

BASE is created

SIDE WALLS

extracted the surface

 

  untrim the surface

 

Extrapolate the surface

Trim the  surface

offset to the thickness

Fillet is provided and SIDE WALL is created

TOP WALL

extracted the surface

 

Extrapolate the surface

 

offset to the thickness

extracted the surface

 

untrim and Extrapolate the surface

offset to the thickness

OUTER FLANGE

extracted the surface

Extrapolate the surface

untrim the surface

Extrapolate the surface

Join the surface

offset to thickness

splitthe surface for trimming

trimming the surface

Join the surface and OUTER FLANGE is created

 

FINAL TRIM

 

Fillet is provided

CLASS B SURFACE is created 

CLASS C SURFACE

CLASS C SURFACE

The first step is to create the boundary of the CLASS-A surface 

boundary is extracted

reference curve is extracted

c surface is created is using sweep function

C SURFACE IS CREATED

COMPONENT

trim class B and Class C

Join with class A

COMPONENT IS CREATED

TREE STRUCTURE

PART BODY

Close Surface feature usedto make a solid body from the surface

 

DRAFT ANALYSIS OF COMPONENT

Change the view to material mode for draft anlysis

 

draft analysis is done using featured draft analysis tool

Use the compass fucnction to aling the compass to the tooling direction and lock the direction using lock function in the draft analysis tool bar

the surface is showing green colour so that the surface clears the minimum draft angle of 3 degree

By using the analyses under the running pointwe can check  draft angle  on the individual faces. It shows how much draft on specific points when we move the cursor point.

Green colour - above 3 degree positive draft

Red colour -between 3 and 0

blue colour- below 0 degree

CONCLUSION

• Created the Coin Holder component using the given Class-A surface.
•  the tooling axis for the given Class-A Surface is created which meeting the requirements of the draft angle
•  Draft analysis is done on the CLASS A surface
• Draft analysis is done on the model. 
• Using the Close Surface feature  solid body is created from the surface
• Publications: Tooling Axis Class A, B, and C surface and closed surface