Week 8 - Challenge 4 - Bumper

BUMPER DESIGN :-

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. 

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 bod

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. 

Class C Surface Creation-

What Class C Surface does, is join the both Class A & Class B Surface. So to create the Class C Surface, first create boundaries using 'Boundary' command with using edges of Class A Surface. And then create a surface using 'Sweep' command at a angle of 90 deg. with class A Surface using those boundary. It might create error when try to make sweep with one single boundary of Class A Surface edge, so for that case we have to take several boundaries according to fisabilioty. And then trim those sweep surfaces with class B surface to make sure there is no excess surface beyond class B surface. So my final Class C Surface was-

Solid Body Creation-

To create solid body of that closed surface, make sute there is no open edges. If there is open edges then it would not be possible to create solid body. After make sure, go to part workbench and make the closed surface part a solid body using 'Closed Surface' command. this operation must be inside a 'Body' set not inside a 'Geometrical Set'. So my final solid body look like

Views of final model-

Isometric view

 Front view

 Side view

Top view