Challenge

Week 8 - Challenge 4 - Bumper

Bumper Report

Aim:

To create Tooling axis and Conduct Draft analysis for both the Class A and Final Solid part.

Objective:

Bumper

To create the Final Solid Part by using the given Class A.
To create the Tooling Axis for the Class A and Final Solid Part.
To Draft analysis the obtained Final solid part and Class A using the created Tooling Axis.

Introduction

Tooling Axis

Draft Analysis

The draft analysis is done on the basis of the Tooling Axis in order to find whether the final product is done as per the Design rules.
The Draft angle which is assigned to the Tooling Axis defines the analysis.
The Nominal Draft angle for the plastic product is 3 degree.

Class A

Class A is the aesthetic surface.
Class A is created on the basis of a concept sketch or by the predefined shape on basis of the design engineer and customer requirement.
Class A is given to the Product design engineer in order to get the final solid part.

Class B

Class B is the surface that is created by the product design engineer in order to get the final product from the class A surface.
Class B is created based on the thickness that the final solid part should be.
In other words, Class B is an Extended version of Class A with some thickness gap between them.

Class C

Procedure:

Class A

Tooling Axis

The tooling for this can't created by using bisecting method.
The tooling is created here by Axis method.
In this the axis is selected where all the feature in the class A is clearly visible.

Draft Analysis on Class A

Class B

The class B is created by offsetting the derived Class A to 3mm.
By offseting the Class A, some of the fillet in class A will not offset.
Then for that part the fillet is speratly created.
The fillet is created by creating the edge in that particular area.
Therefore the edges on that particular area is extrapolated.
The edge fillet option is used.
The fillet radius calculated from class A and done some calculation based on its direction of fillet will go while offseting.
The fillet goes inward the fillet radius of class A, the wall thickness will be subracted.
The fillet goes outward the fillet radius of class A the wall thickness will be added.
In some places the face won't be avaible due to offset, So in that area multisection is used.
Thus the class B is derived.

Class C

The class C is created from the class A using the sweep.
The boundary of class A is taken.
Then 'with draft direction' is selected in the sweep tool.
The tooling axis is used for draft direction and boundary as profile.
The class C can't be created in a single stoke due various angle and shape.
Therefore the boundary from class A is divided using the limit option init.
The default draft is 3 degree but in some places draft angle is changed to 90 degree.
Then for some places 'with reference surface' option is used.
This option requires the profile, guide and the surface.
Then in some area multisection is also used.
Then by joining or triming them Class C is created.
Then for the hole sperate sweep is done and class C is created.
The Class C is created.

Final operation

The Created class C is joined with the class A.
The joined class A and class C is trimed with class B.
If class A and class C join can't be trimed with class B then extrapolate the class B to some millimeters.

Solid Body

The solid body created by using closed surface.
The design which created is switched from 'genrative shape design' to 'part design'.
Then closed surface tool is used to convert the plastic design model to solid form.

Draft analysis

Structural Tree Images

Conclusion

Ship work like this
in your own course.