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.

Take the Thickness of the component to be 3 mm

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. Today, standard passenger vehicle bumpers have a rigid reinforcing bar under the outer cover, with sections of compressible foam or plastic underneath.

A bumper is made up of four parts:

• Bumper cover.
• The bumper absorber.
• The bumper reinforcement bar.
• The bumper mounting system.

The first car bumpers were created all the way back in 1901 and consisted of metal beams attached to the front and rear of the car to protect it during a low-speed collision. Designed to protect the expensive and fragile components like the headlights, tail lights, hood, exhaust, and cooling systems, early metal bumpers were focused on sheer resilience.

Modern consumer production cars have almost completely switched over to plastic bumpers. Modern car bumpers are made from thermoplastic olefins, a blend of plastic molecules, rubber, and a reinforcing filler like carbon fiber or calcium carbonate. This blend of materials creates a scratch and impact-resistant plastic that can bond with a wide range of paints and finishes, making it ideal for vehicle bumpers.

Plastic is the preferred material for modern car bumpers for several reasons. First and foremost, plastic is much lighter and more aerodynamic than metal, which improves the car's fuel efficiency. Plastic is also easier to shape, which is useful during both the manufacturing and bumper repair process.

Bumpers of most modern automobiles have been made of a combination of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) called PC/ABS.

To design a car bumper Plastic component through the given Class-A surface by creating a tooling axis and draft analysis of the given surface.

DESIGN PROCEDURE:

• To setup the class-A surface and to creating a tooling axis
• add draft angle
• To create a base surface of model
• To create a B-surface
• To create a C-surface
• To use close surface for creating a solid part model

CLASS-A SURFACE:

TOOLING AXIS:

direct method

• For this model, to use a line at mid-point of the base of the coin holder
• Due to perpendicular walls of the class A surface
• I use intersection and create center point there.

CREATING CLASS-B SURFACE:

• To offset the class-A surface along 3mm for to create a B- SURFCAE.
• Surface Gaps can be filled by using a fill tool and multi sectional tool

When surface A offset 3mm for surface B so in which little little surface patch create there so we can solve it ilke this

all the process ready surface B and all the fillets done there

SURFACE-C Creation

Surface that joins class-A and class-B surfaces is class-C surface. 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 at one shot. Hence, we need to create smaller curves using multi-extract command and then create sweep of 90 degree with reference to the surface option. sweeps at the midportion of the bumper should have a 93 degree vaue to pass the draft analysis.

• Join the sweeps using the join command and the class-c surface is created.

Creating the final surface of Bumper

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

Go to the part design work bench and using the close surface command create the base bracket solid part body

The expanded Tree Structure for the geometrical set and the Part Body

Draft analysis of the Final part body

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

• Change the view mode to material shading
• Align the Compass with Tooling axis.
• Lock the draft direction and perform the Draft analysis.

Conclusion

I have successfully created the class-B and Class-C surfaces of Bumper using the given Class-A surface along with the tooling axis in the CATIA surface workbench.