Week 8 - Challenge 4 - Bumper

BUMPER DESIGN :-

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.

Class A Surface-

Class A Surface is the asthetic sutface that is created through scaning of clay model. This Class a Surface is a input CAD model for part design.

Class B surface-

Class B surface is created in a certain distance according to the thickness of the part. Class B Surface contain all engineering compoonent.

Class C Surface-

Class c Surface joins the Class A & Class B Surfaces

Given Class A Surface-

TOOLING AXIS:

• Tooling axis can be classified into two methods

1. 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

DRAFT ANALYSIS:

• The Drafting analysis was performed on the class-A surface by using the Feature Draft Analysis command.

• Using this command, the compass was set on the main tooling axis and the Draft angle was changed to 3 degrees.

Class B Surface Creation-

To create Class B Surface first Extract The class A surface using 'Multiple Extract' command. Then Offset The extracted surface with propere distance and direction(Downerd), where distenmce is nothing but the thickness value of the part. In this case some part of the surface might not be offseted. For those areas we have to use 'Multi-Section Surface' & 'blend' command with proper edge and guide curve and have to create those areas. Sometimes it might need to extract that perticular area of surface and then follow the same process to create the surfacxe.

Class C Surface Creation-

What Class C Surface does, is join the both Class A & Class B Surface. So to create the Class C Surface, first create boundaries using 'Boundary' command with using edges of Class A Surface. And then create a surface using 'Sweep' command at a angle of 90 deg. with class A Surface using those boundary. It might create error when try to make sweep with one single boundary of Class A Surface edge, so for that case we have to take several boundaries according to fisabilioty. And then trim those sweep surfaces with class B surface to make sure there is no excess surface beyond class B surface. So my final Class C Surface was-

Final Closed Surface-

After creating all surfaces, join them togather using 'Join' command. And my reasult is

Draft Analysis-

Draft analysis is a most importent thing for a part body design. Its reasult says that the perticular body is manufacturable or not. Even it also analise that how simple or complex will be the manufacturing process. So to do that analysis first we have to create a tooling axis that will be along the movement of mould open and close axis.

Solid Body Creation-

To create solid body of that closed surface, make sute there is no open edges. If there is open edges then it would not be possible to create solid body. After make sure, go to part workbench and make the closed surface part a solid body using 'Closed Surface' command. this operation must be inside a 'Body' set not inside a 'Geometrical Set'. So my final solid body look like-