Week 8 - Challenge 4 - Bumper

OBJECTIVE

• To design Bumper as per automotive industry Standard.
• Create a tooling axis for the given CLASS-A surface.
• Create B Class and C Class surfaces
• Create a final surface model and convert it into a solid body using the 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

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.

Procedure for creating the tooling axis

The tooling axis represents the opening and closing of the mold core and cavity during the manufacturing of the components. A plastic product designer should consider the best tooling direction to cut down the cost of the component very less.

Method opted for creating tooling axis for the bumper

• Check the best tooling direction for the given surface.
• We can find out the best tooling direction by cross-checking all three axes.

• Here we can find out that the best tooling direction for the pumper class-A surface is along the x-axis direction
• The method I choose to create the tooling axis is first to extract a surface and create a midpoint on that surface. Then introduced an axis system at that point.
• Then created a line with the point and direction along the x-axis.

• Another method is by creating an intersection along the y direction. And then create lines on the walls and then create a bisecting line with the lines on the wall and point created earlier. We will get an axis that will satisfy the draft analysis requirement.

Draft analysis for the given CLASS-A surface

The Draft Analysis is a command that enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed 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.

Procedure for Draft Analysis:

• The part created has to be changed to material mode in display frame
• Then by enabling compass definition the axis system is pan along the direction of the part and aligned in line with the tooling direction
• Lock Direction is applied that fixes the compass and then the mode dialog box is formed by snapping at any point on the part
• The Color Codes are classified and Draft Angle are applied
• The green color shows the positive daft tooling direction and the given surface passes the draft analysis.
• Click on the analyses under the running point to check the draft analysis on the individual faces. It shows how much draft on specific points when we move the cursor point.

SURFACE-B CREATION

Class-B surface means the thickness of a part it is not visible and is inside part. In other words, the 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, and extrapolate.
• To ensure the continuity of the Class-B surfaces checks the boundary command to find out the boundary.
• Hence class-B surface creation is done.

SURFACE-C Creation

The surface that joins class-A and class-B surfaces are class-C surfaces. 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 in one shot. Hence, we need to create smaller curves using the multi-extract command and then create a sweep of 90 degrees concerning the surface option.

Creating the Closed surface of the Bumper

• the First step is to join the CLASS-A surface with the CLASS-C surface.
• Then Trim the Joined surface with CLASS-B surface to achieve the final Bumper surface.

Creating the Closed Body of the Bumper

Go to the part design workbench and using the close surface command create the Bumper solid part body

Draft Analysis of Final Product: