Challenge

Week 8 - Challenge 4 - Bumper

MMohd Imran16 Mar 2023

TITLE OF THE PROJECT

BUMPER DESIGN

AIM

To create a body of Bumper from the input given which was the A-surface of a Bumper. The created body should be a closed solid volume which should be feasible for manufacturing and Tooling. The draft angle and draft analysis of the component should be done.In model, proper tree structure to be maintained and publications of Tooling axis,A,B and C surfaces to be done.

INPUT GIVEN:

A-Surface
Thickness of component is 3.00mm
Draft angle is 3 degrees.

INTRODUCTION

In the Bumper Design Create the Bumper Plastic component through the given Class-A surface. To begin with, 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.

OBJECTIVE

Creation of tooling axis.
Draft analysis of Class A Surface.
Creation of B Surface by given Class A Surface.
Creation of C Surface.
Creation of solid part by using closed surface.

TOOLING AXIS

Tooling axis define as a

Angle 1 about X, Angle 2 about Y: The tool axis is rotated an Angle 1 about the x-axis, then rotated an Angle 2 about the y-axis.
Angle 1 about Z, Angle 2 about X: The tool axis is rotated an Angle 1 about the z-axis, then rotated an Angle 2 about the x-axis.
Angle 1 about Y, Angle 2 about Z: The tool axis is rotated an Angle 1 about the y-axis, then rotated an Angle 2 about the z-axis.

CREATION OF TOOLING AXIS

Tooling axis is the direction in which a core or cavity of mold opens. This Axis is very important to determine the orientation of the component in mold, core and cavity design.

The tooling axis is created by the inertia method by using the steps as follow

Click “Measure inertia” and select the A-surface
Click “Create geometry” in the Measure Inertia window.
In the Creation of Geometry window, select Non-associative geometry.
Click “Center of Gravity”
The Inertia point is created.

The component is viewed in all axes namely X,Y and Z.
It is determined that the X-axis will be the direction for the Tooling axis and a line is created Using the CG point and X-direction as direction of the line.

DRAFT ANALYSIS OF CLASS A SURFACE

Draft analysis of the surface is carried to check if the surface or part can be manufactured with the required draft angle.

Draft angle is needed for the component to clear the core and cavity surface as it would have shrunk towards the center while cooling.

The draft angle in this design is 3 degrees. As A surface is a single surface there won't be much difference in color. The draft analysis of A-surface

Go to insert< analysis< feature draft analysis.
Align the tooling axis with the compass.
Click on the surface and see that the surface is within the permissible limit of the draft values.
The surface should be green and in the column proper value (3deg) should be inserted.

DRAFT ANALYSIS OF PART BODY

The final solid part body has to be analyzed using Draft analysis. This is done to check if all the areas of the body are satisfying the draft angle which is 3 degrees.

A draft angle is a taper applied to the vertical walls of the injection-molded component to assist with releasing the part from the mold.

Draft angles are a required feature of injection-molded custom parts. A functional part for injection molding has to have draft angles that face both the cavity and core sides. This will reduce the risk of damage to the parts and ensure that they can be ejected from the machine.

The Bumper body is checked using Analysis and images for it are shown below.