Week 8 - Challenge 4 - Bumper

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

Input Class A Surface:

DRAFT

Draft angle is nothing but providing some tapered portion to the part for easy removal of the component from the mold during manufacturing. This is especially done in the case of plastic component design having a complex shape. Mostly the 3-degree draft angle is provided but it can vary depending upon the component which is to be designed

In our case of Switch Bezel design, the draft angle is 3 degrees the draft analysis is done during the design of the component to check the feasibility of the product.

Before providing a draft angle we need to decide on the tooling axis also known as the molding axis considering the faces which can cause issues while manufacturing.

CREATION OF THE TOOLING AXIS :

TOOLING AXIS :

It is nothing but the direction in which the mold opens and closes the draft angle needed to be provided by considering this tooling axis.

We can create a tooling axis by using the bisecting method.

BISECTING METHOD :

This method is used for the generation of the tooling axis for that purpose first we need to decide the direction of molding and then we create one dummy tooling axis for the reference to the purpose.

In this method, we select the surfaces which can create problems and take intersections with respective planes in the x and y-direction. By using these intersection curves we draw two lines and then draw a bisecting line from these two lines in the x-direction and y-direction.

After completing this we need to draw a final line bisecting these two tooling axis in the X and Y directions to get our final output.

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 the three axes
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• Here we can find out that the best tooling direction for the pumper class-A surface is along x-axis direction
• The method I choose to create the tooling axis is first extracted a surface and create a midpoint on that surface. The introduced an axis system on that point.
• Then created a with the point and direction along x axis.
• Here both the outer flanges have 5.1-degree draft with respect to the axis created. Hence going with the axis created will not make any difficulties during the draft analysis.
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Draft analysis report for both the given Class-A surface and the final plastic component :

DRAFT ANALYSIS FOR THE CLASS-A SURFACE :

In the above images, the draft analysis of the Class A surface has shown the draft angle should be more than 3 degrees and this can be clearly observed from the above images that the surfaces have an angle of more than 3 degrees.

DRAFT ANALYSIS FOR THE SOLID BODY:

Isometric, Front, Side, and Top View: