Week 8 - Challenge 4 - Bumper

Objective: The main objective of this challenge is to create a solid body of 'Bumper' with the help of the closed surface method by using the 'Generative shape design' workbench in CATIA V5. Performing the 'Draft Analysis' on the solid part body of the Bumper.

Overview:
Initially, we need to offset the given Bumper class A surface in the inner direction to the required thickness (here the thickness is 3mm). After that, we need to close the patches on the offset surface of the bumper, the patches are formed due to the fillets on the Class A surface. Once all the patches are closed properly join them together to make a proper class B surface and now sweep the boundary of the class A surface to trim with the class B surface to make a closed body. By using the closed body command in the Prat workbench we can get the solid body from the closed surface of the Bumper. Now, again went back to the surface workbench to perform the 'Draft analysis' for the solid body.

TOOLING AXIS:

To create the tooling axis, I extracted a surface from class A and created a point in the middle of the surface by using the point command and created a line at that point through the x-axis. Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not. If, in the draft analysis check the surface highlighted with green colour on both sides of the surface the tooling axis is in the correct position and direction.

CLASS B SURFACE:

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 3mm, so I offset the class A to 3mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multi-section surfaces command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface.

few gaps in surfaces becyse of fillets also we can say patches were there after offset

After using of fill and blend commmand we will join and and remove the unwanted the patches but

TIP is this here Mostly We Fill and Blend command not used in Industry because its will never updated in future if product surface or size will increas .

also we can use Sub elements to remove by join command and second is extract extrapolated and apply fillted .

finally our class B surface looks like this

CLASS C SURFACE:

To create the class C surface concerning the boundary of the class A surface, I used the sweep command. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweeped surfaces until both surfaces got intersected properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the centre hole of the bumper.
Now, join both class A and sweep boundary to get the complete class C surface.

Sweep command shows error sometimes If any issue is there so I did One edge by edge boundary limt 1 and 2 and sweep them .

we will be take care of direction and check boxes which I marked

also take care of length , length should be the more than the offset length because we can trim easily

Now, unhide the class B and class C surfaces. Check whether all the sides of class B and Class C surfaces are intersecting properly with each other, to get a closed surface by trimming class B and class C surfaces. If the class B and class C sides are not intersected properly, we need to extrapolate the sides of the class B surface which are not intersecting with the class C surface. Now, check class B and class C surface boundaries whether all the sides are intersecting or not with each other. Once the surfaces are intersecting properly trim them together to get a closed surface.

we will Take care of this

A SURFACE + C SURFACE - B SURFACE

(+) MEANS JOINS (-) SHOWS TRIM

ALL FOUR VIWES

DRAFT ANALYSIS