Challenge

Week 8 - Challenge 4 - Bumper

SSidhartha Sankar Sahu15 Mar 2023

AIM : Creation of a Bumper Plastic component of thickness 3mm through a given Class-A surface.

REPORT :

WHAT IS TOOLING AXIS : The direction in which the mold or core and cavity opens is the tooling axis.

HOW TO CREATE A TOOLING AXIS :

1) Before creating a tooling axis , as a preventive measure check the Connectivity of Class-A surface. it can be done by using the "join" or "boundary" command. using these command we can identify any unnecessary openings of the class-A surface.

no unnecessary openings are found.

2) visually analyse which is the best possible way to create the tooling axis , considering avoiding side cores, easy ejection of component from core, easy flow of molten plastic inside the cavity.

tooling axis along 'y' & 'z' is impossible here , and considering the flat surface in the number plate area , 'x' axis is perfect for tooling axis.

tooling axis creation using Bisecting method :

As per its name , in bisecting method we bisect lines which are along the class a surface walls which we think might create an issue while manufacturing , as the result of the bisection we get a line which clears each and every sub surface of the class a . and we consider the line as tooling axis for the component.

but for this surface there are multiples walls to consider , that is why we are performing along axis method . as we can clearly see along 'x' axis the class a is completely visible , but not along 'y' & 'z' , so we will create tooling axis along 'x' direction.

- extracted a flat surface along 'x' axis .

- created a point in the middle of the surface .

- using point-direction command created a line / tooling axis on that point along 'x' direction.

- then to confirm the tooling axis is clearing every surface of the class a or not , performed draft analysis.

Draft analysis :

After determining the tooling axis , Draft analysis is done.draft analysis is used to check whether the desired draft angle is maintained or not. Compass is used in the draft analysis command to define the draft direction. as an output of this operation , we will be receving a colored range table , which will clearly show which surface of the component is getting cleared or not with the required draft angle , and with that result we can modify the surface.

Draft analysis for class-A :

every surface is clearing with 3 degree draft angle .

Draft analysis for final plastic component :

necessary surfaces are clearing with 2.9 degree draft angle .

creation of final component from class-A surface :

Created a class-b surface from class-A surface by first offseting the class a with 3mm, as a result got a surface with some unformed fillets and unformed surfaces . using extrapolate and multisection like commands , created a good quality class b or repaired the unformed offset.

Then created class-c from class-A by first taking the boundaries from class a then sweep them along class-b and then combined the sweeped walls /class c with the class-A surface.