Week 8 - Challenge 2 - Base Bracket Design

                                                                                   BASE BRACKET DRAFT ANALYSIS

    THIS IS THE CHALLENGE OF THE SURFACE AND PART WORKBENCH , WHERE MOST OF THE WORK IS PREFFERED TO BE DONE IN THE SURFACE        WORKBENCH.

  KEY TASK ACCOMPLISHMENT / OBJECTIVE .

1. Create the tooling axis direction  for the opening of the core and cavity.
2. Create the class B surface for the attachment.
3. Create the class C surface for the providing thickness to class A surface.
4. Creating the closed body from the surface body.
5. Draft analysis of class A and closed body. 

  INPUTS:

• We have class A surface as the input for accomplishing all the key targets mentioned in the objective as a plastic product designer.

  TOOLING AXIS CREATION :

1.  The tooling axis direction is very much important from the design point of view as it decides the direction of moulding or opening of core and   cavity.
2.  One should visualize the component in all 3-Dimensional axis and decide the probable dummy axis which is Z axis for base bracket.
3.  Next task is to check the clearance of the respective component with draft in both zx and yz planes.
4.  Create a point centre to the surface / circle of the hole and create the axis system.
5.  using the intersect command intersect the yz plane with the class A to get the clearance details in the yz plane .
6.   extend the draft edges and create the bisecting line to get the tooling axis in the yz plane.
7.  The component is cleared in zx plane visually as there are no slots and holes, which will not affect the moulding direction.  
8. 

  CREATING THE CLASS B SURFACE:

1.  Class B surface is the surface which is created with the help of class A surface as the reference.
2.  The the class B surface is the surface where all the necessary attachments and supports of the component is made .
3.  The main parts without the edge fillets are extracted and untrimmed and then they are extrapolated for better view.
4.  The extrapolated parts are then made offset with reference to the class A with the thickness of the component, here thickness of the component for base bracket is 2.5 mm.
5.  The offset surfaces are then trimmed to attain the class B surface.
6.  The final class B surface must have the edge fillets similar to the class A and fillets must be given properly with a thought of maintaining same   thickness throughout avoiding the flow line defects.

  CREATION OF CLASS C SURFACE:

• The class C surface is the surface which is created to provide thickness to the class A surface with the help of class B surface.
• The class C surface is the middle portion of the class A and class B surfaces.
• The class C is created with the help of the sweep command in surface workbench.
• The class A surface's boundary is taken as profile (guide curve) and then tooling axis created is taken as direction of the sweep in subtype draft direction
• The draft angle for the sweep is 3 degrees.
• The holes are created using the same axis and draft angle.
• The attained sweep is joined with class A surface to obtain the class C surface.
• The final trim is obtained by trimming the class B with the class C surface.
• The  final check to ensure the proper clossness of surface with the boundary command .

  CLOSED BODY CREATION:

1.  The final trim surface is then openend in the part workbench for providing the closed surface for analysis.
2.  The surface based feature in the part workbench is utilized for creating the closed surface.

  DRAFT ANALYSIS OF THE CLASS A AND CLOSED BODY :

1. The draft analysis is done to ensure that the draft in permeasible with the design consideration.
2. The draft analysis is done by changing the visualization mode to customize and select shading as material.
3. The draft based feature enables us to visualize and examine the draft.
4. The draft window is has two tables one is for examining the draft and other one is the colour code.
5. The draft value is set in the colour code window with each colour having their own significance.
6. The red colour indicates the positive draft less than minimum draft where as the green colour indicates the minimum draft.
7. The blue colour indicates the negative draft.
8. For visualizing the draft the compass is aligned with the tool axis direction and the cursor is then made clicked upon the surface for viewing the draft.
9. The quick view in display window enables to examine the draft value throughout the surface.
10. Here both class A and closed body are given the minimum draft as 3 degrees.

 DRAFT ANALYSIS OF THE CLOSED BODY IN ALL THE VIEWS:

  TREE STRUCTURE WITH PUBLICATION