Week 8 - Challenge 4 - Bumper

BUMPER DESIGN

• Objective: -

1. Create the BUMPER Plastic component through the given Class-A surface.
2. 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.
3. The inner panel is subjected to the draft analysis to ensure whether it is satisfying the deep drawing requirements for the tooling direction that is created in the design.
4. Perform the draft analysis for each component & reinforcement.

• Introduction: -

Product design starts with requirements. The designer will sketch the product based on your requirements. He then uses advanced CAD software to transform the 2D sketch into his 3D model with proper dimensions. Another important aspect of design is that any designed product is manufacturable.

Therefore, the designer's role is to design products that are easy and inexpensive to manufacture.

This is where Design for Manufacturing [DFM] and Design for Assembly [DFA] play an important role in product development.

The design development process continues until the design meets the customer's requirements.

The product to be developed this time is car back door.

TOOLING AXIS INTRODUCTION:

The direction in which the mould or core and cavity open is the tool axis. To easily visualize all openings, create boundaries or just use the connectivity option to see the connectivity of the surfaces. Visually analyse the optimal tool axis.

1. First we performs a connectivity check to see if the given class A surface is It seems that there are no discontinuous boundaries.
2. Create a line as shown in below image justifies all of the surfaces for the part, hence declares as Tooling Axis.

PROCEDURE OF BUMPER DESIGN:

1. B Surface Creation
2. C Surface Creation
3. Trim C-A & then B surface formed complete closed surface
4. Use closed surface command to convert into thick solid

1. B Surface Creation
2. Tocreatea “ClassBsurface”,offsettheclassAsurfaceaccordingtothethicknessrequirement(herethe required thicknessis3mm,sooffsettheclassAsurfaceby3mm).
3. Once the offset is created, we can observe some patches on the offset surface by getting the boundary of the offset. These patches are formed by classA surface fillets.
4. Here I have offseted the class A surface and my result was-

Extract the support surfaces from class-A surface.

• Use join command with unselect connectivity & remove unnecessary fillet surfaces from the offset surface.
• Extrapolate the offset surface with point continuity & trim them together.
• Use iron box technique to form required feature, trim them together.
• Used appropriate fillets to form basic B surface.

5. Complete class-B Surface

• Use extrapolate command for extension of open boundary edges to create single piece of class-B surface.

1. CLASS-C SURFACE

• This is the interface for class A and class B
• Create a class-A surface boundary using the Boundary
• Use the Sweep command to create a Class C surface along the draft direction with a draft angle of 3 degrees to the tool
• Extrapolate and trim hole features from a class-A

1. CLOSED SURFACE

• Publish class-A, class-B, class-C surfaces and tooling axis.
• Join all the surface together.
• Create closed surface.

Trim Class-A & Class-C surface first then trim it with Class-B surface would form complete Base bracket.

1. Draft Analysis

For Class A Surfaces

For Complete Part

Limiting draft angle = 3 degrees

Draft analysis from the selected tooling axis location.

• Conclusion: -

The Bumper Design is completed w.r.t Class-A surfaces & draft analysis also done completely with the help of CATIA software.