Week 8 - Challenge 4 - Bumper
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.
Draft Analysis ?
The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line.
Draft angles ?
Draft angles are very important in thermoforming product design. If the product is formed onto a female or negative mold, it shrinks away from the mold sidewalls. As a result, true female or negative products can be thermoformed with vertical walls having zero draft angles. If the product is formed onto a male or positive mold, it shrinks onto the mold sidewalls. A draft angle of 1–5 degrees is recommended for all male or positive products.
here we are taking minimum 7degree of draft angle because our die should not get damage and we should get a finish good product. In some area we cannot avoid negative draft. So bending operation is provided for the manufacturing process, because deep drawing cannot be done at the negative draft area.
Tooling Direction for Plastic Part
Tooling direction is main consideration for plastic part and mold parts because it defines movement of mold part and possibility of plastic part to come-out from mold part (Core and Cavity).
Tooling Direction:-
In Molding machine arrangement is given to open the mold along a direction which is known as Tooling Direction.
In other words. The mold is built from two separate halves (Core and Cavity) and tooling direction basically define the direction of mold pulls apart.
Tooling direction is known as primary direction.
WHAT IS CLASS A, B, C SURFACES ?
Class A:- Styling or A class surface are the terms used in plastic product design. That means the surface of a component that is smooth (aesthetic) or visible side to the human eye after the part is assembled.
Class B:- It is an engineering surface, and it gives you thickness from class A surface
Class C:- when Class A and Class B surfaces are joined along the tooling axis it is called class C surface.
FOR CLASS A SURFACE CHECKING WHICH IS THEBEST DIRECTION FROM WHERE ONE CAN SEE MAXIMUM EDGES FROM THE NORMAL VIEW .
THEN EXTRACT THAT SURFACE CREATE A POINT AND CREATE A LINE FREM THAT.
FOR CLASS B SURFACE USE THE OFFSET COMMAND.
SOME PATACHES CAN BE SEEN THIS PATCHES CAN BE REMOVED BY
WHEN WE HAVE 2 DIFFERENT SURFACE THEN EXTRAPOLATE AND THEN TRIM THEM.
THESE CAN BE DONE BY EXTACTING THE SURFACES.
OTHER METHOD OF REMOVING THE PATCH CAN BE DONE BY USING DIRECT FACE TO FACE FILLET COMMAND.
THIS IS THE CLASS C SURFACE WHICH IS SWEEP FROM THE CLASS A SURFACE WITH THE TOOLING DIRECTION SOME PLACES USED WITH RESPECTIVE TO SURFACE ALSO.
{ BOUNDRY- SMOOTCURVE-SWEEP}
THIS IS HOW CLASS A AND CLASS C SURFACE LOOK WHEN JOIN.
FINAL SURFACE.
FINAL BODY
THE FIRST DRAFT ANALYS IS IS DONE ONT THE CLASS A SURFACE TO SEE WETHER THE TOOKING AXIS IS CORRECT OFR NOT HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE
DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE. THIS MEANS THE TOOLING AXIS IS CORRECT.
HERE THE SECOND DRAFT ANALYSIS ID DONE ON THE SOLID BODY HERE IT IS SHOWING GREEN COLOR WHICH MEANS THE DRAFT ANGLE IS 3 OR MORE THAN 3 DEGREE.
THE BLUE COLOR MEANS THE DRAFT ANGLE IS 0 DEGEE WHICH IS MANDATORY FOR THE SOLID BODY BASE SIDE. AND WE DO NOT HAVE RED COLOR ON THE SURFACE MEANS THE BODY IS GOOD FOR THE MANUFACTURING .
RED LINES ARE OF FILLETS WHICH IS ACCEPTABLE.
THANK YOU