Challenge

Week 8 - Challenge 4 - Bumper

MMohan Kumar A14 Sept 2022

BUMPER DESIGN

AIM:- Main purpose is to perform to make a model from the supplied class A area.

CLASS A- SURFACE:- A surface made by the designer is given as input to the plastic modeler to work on It is an aesthetical surface and the external surface.

CLASS B- SURFACE:- A surface below a certain thickness of the Class A surface is a Class B surface This is the surface that contains the technical features of a model.

CLASS C- SURFACE:- a surface that encloses Class A and Class B characters is a Class C surface.

METHODOLOGY:- In this model, we have focused on the following things:-

1. Tooling axis

2. Draft analysis

3. Class-B surface

4. Class-C surface

5. Making a solid model from the surface.

6. The following tools were used to reach the final step.

7. Extract.

8. Un-trim.

9. Trim.

10. Extrapolate.

11. Offset

12. Edge fillet

13. Boundary

14. Sweep

15. Join

16. Close (part design)

DRAFT ANALYSIS:-

First, we analyze the model, then we select a dummy axis in the x and y directions. As we crossed each other to proceed, we observed that the lateral walls do not receive any rough edges. Therefore, we suppose the normal axis at the base surface and parallel to the lateral walls. That is definitely going to create problems because we have to provide a minimal draft. As the class A surface is made by another designer only it is authorized to make changes, so we look at this to complete the wallet for practice. Now let's insert < analysis < draft analysis and follow the usual procedure for making the analysis. Align the compass and click on the surface and as intended, the model is mainly in red color, i.e. negative in relation to the axis. To correct it as best as we can we moved the compass a bit till we got most of the surfaces in green and locked that position.
After hitting ok, we change the direction of the line from the z-axis to the compass direction. The axis will align itself accordingly.

NOTE: as the side wall does not have a draft, this result was expected and a few areas need correction. But still, we are moving forward to
complete the model.

CLASS -B SURFACE:-

We have divided the entire model into the base, side walls, inside side walls, and outer flange and worked on them one by one Everywhere we follow the same procedure i.e. extract, un-trim, extrapolate, trim and offset. First base, then side walls. To avoid confusion, we trimmed both together and made them one. Also, the fillet was given.

CLASS-C SURFACE:-

To create the class C surface concerning the boundary of the class A surface, I used the sweep command. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweep surfaces until both surfaces got intersected properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the center hole of the bumper. Now, join both class A and sweep boundary to get the complete class C surface.

FINAL MODEL JOIN CLASS A + CLASS C:-

Now, unhide the class B and class C surfaces. Check whether all the sides of class B and Class C surfaces are intersecting properly with each other, to get a closed surface by trimming class B and class C surfaces. If the class B and class C sides are not intersected properly, we need to extrapolate the sides of the class B surface which are not intersecting with the class C surface. Now, check class B and class C surface boundaries whether all the sides are intersecting or not with each other. Once the surfaces are intersecting properly trim them together to get a closed surface.