Week 8 - Challenge 4 - Bumper

Week 8 - Challenge 4 - Bumper

AIM

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

• To design Bumper as per automotive industry Standard.
• Create tooling axis for the given CLASS-A surface.
• Create B Class and C Class surfaces
• Create final surface model and convert it into solid body using close surface command in the part design workbench.
• Perform draft analysis for both Class-A surface and Final part body.

DESIGN METHODOLOGY

Skin data would be provided to us by the styling team to us.

Class-A surface means visible surface. It gives the aesthetic of the component which is created by the styling team and gives to the part design engineer to create the part with all engineering aspects.

The first step is to check the continuity of the class A surface. This is to ensure that there is no gap between surfaces. If we find any then we should fix that first.

Class-A continuity check

Analyse the class A surface through visual inspection.

To make sure that the given surface has no gap in between them. We can check it also with the help of Join or boundary commands.

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.

Draft analysis for the given CLASS-A surface

The Draft Analysis is a command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

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SURFACE-B CREATION

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 3mm inward direction.
• Rework on the patches and discontinuity of the offset surfaces using the features like extract, multi-extract, sweep, multi-section surfaces, extrapolate.
• To ensure the continuity of the Class-B surfaces check the boundary command to find out the boundary.
• Hence class-B surface creation is done.

SURFACE-C Creation

Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled

Since it is a complex class-A surface, we cannot simply create the class-A boundary curve and sweep it at one shot. Hence, we need to create smaller curves using multi-extract command and then create sweep of 90 degree with reference to the surface option. sweeps at the midportion of the bumper should have a 93 degree vaue to pass the draft analysis.

after we will join classs a and c

finaly join the class a and b and c

checking final draft analysis

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.

final output like this

diffrent views