Week 8 - Challenge 4 - Bumper
BUMPER DESIGN:
AIM: To create the Bumper Plastic component through the given Class-A surface by creating a tooling axis meeting the requirements of the draft angle and to perform the Draft Analysis on the solid model at the end. The thickness of the component to be taken is 3mm.
GIVEN CLASS A SURFACE:
The Class A surface is given to us as an input which is checked for any open profiles inside the geometry using the "Boundary" command before starting the construction of Class B and C surfaces. This is nothing but checking the quality of the input.
REPORT ON DRAFT ANALYSIS AND TOOLING AXIS CREATION:
DRAFT: It is the degree of taper that is incorporated into the side wall and cores of the die cast tool to aid in the removal of a part. Primarily, they function to reduce the friction between the part and the tool as it is ejected. Without draft angles, parts can be stripped, dented, or get stuck in the tool.
The Draft Analysis command enables you to detect if the part you drafted will be easily removed. In the case of plastic injection molded parts it also allows the designer to see if there is enough draft on the part to ensure that it can be correctly grained.
TOOLING AXIS CREATION:
Tooling axis is the direction that the mold pulls apart. It is necessary to create a tooling axis to give draft to the component. Tooling axis is created using the Bisecting Method or Hit and Trail to acquire the required draft. For the given Class A surface, the best tooling direction for the component is chosen by considering the tooling of the final product. It is chosen in such a way that the component is cleared with minimum tooling.
BISECTING METHOD:
In Bisecting Method, an axis is created by bisecting the lines that lie on the opposite walls or faces of the surface which can be done by using intersection of the of the Class A with the plane of intersection. The walls or faces that may probably create a problem during tooling are selected for intersection with the plane. In this model, due to the absence of opposite walls, a base plane is selected and tooling axis is created on the plane in the direction that can clear the tooling easily. I have extracted a base surface and created a point on the geometrical centre of the surface and later created an axis with the plane and point as inputs. The axis is created using "Normal to Surface" type in the line command, i.e. it is normal to the selected surface/plane.
The axis created is renamed to 'TOOLING AXIS' and is then Published for easy reference. It can be accessed in the "PUBLICATIONS" below the tree structure.
DRAFT ANALYSIS ON CLASS-A SURFACE:
Draft Analysis is performed on the Class A Surface after creating the Tooling axis. It is performed to check if the surface clears the tooling.
QUICK ANALYSIS:
FULL ANALYSIS:
From the Analysis, it is clear that a minimum draft of 3 degree is maintained for the Class A surface as the colour 'green' in the quick analysis mode indicates that the surface passed the draft check which can be observed using the colour scale table. The pictures of the Full Draft Analysis of the surface with color scale table are also given.
Thus we can conclude that the Class A Surface clears the minimum required draft angle for tooling.
FINAL SOLID MODEL:
After trimming and joining all the three Class A, B and C Surfaces, the final solid model is created in the part body using the Close Surface tool in the Part Design workbench. This is the required solid component - Bumper.
DRAFT ANALYSIS ON SOLID MODEL:
Draft Analysis is also done for the final Solid Model similar to the anlysis done for Class A surface to check if the body clears the tooling.
These are the results for the Draft Analysis of solid body in quick and full analysis modes.
DRAFT ANALYSIS ON SOLID MODEL IN VARIOUS ORIENTATIONS:
ISOMETRIC VIEW:
FRONT VIEW:
SIDE VIEW:
TOP VIEW:
