Week 8 - Challenge 4 - Bumper

BUMPER DESIGN

AIM

Create the Bumper Plastic component through the given Class-A surface. 

INTRODUCTION

A bumper is a structure attached to or integrated with the front and rear ends of a motor vehicle, to absorb impact in a minor collision, ideally minimizing repair costs. They are designed to absorb impact to the front and rear of vehicles and minimize low-speed collision damage.

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.

FEASIBILITY OF CLASS A

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. 

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 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.

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

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 performing the draft analysis are as follows:

• Change the view mode of the component to be in customized parameter mode and then select the shading mode as materials.
• Then open the featured draft analysis tool from the insert menu.
• Then click on the use the compass to define the current drafting direction and then drag and align the compass on the Tooling axis.
• Then lock the draft direction and perform draft analysis by clicking on the component.
• The green color shows the positive daft tooling direction and the given surface passes the draft analysis.

SURFACE-B CREATION

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 reference surface option. 

Creating the final 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.

Draft analysis of final part

The same procedure for the draft analysis of the CLASS-A surface is followed.

• Change the view mode to material shading.
• Align the compass with the tooling axis.
• Lock the draft direction and perform the draft analysis.

After the whole surface is finished the surface is converted into solid by close surface option.

CONCLUSION

The bumper design has been done by maintaning a proper tree structure.