Week 8 - Challenge 4 - Bumper

Aim:

To 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.

Operation to do:

1. Create Tooling Axis.
2. Create Draft Analysis for Class A Surface.
3. Create Class B Surface.
4. Create Class C Surface.
5. Create Draft Analysis for Overall Surface.
6. Create Closed Surface.

Material used in Bumper :

• Acrylonitrile Butadiene Styrene (ABS).

Why this material is used?

• ABS has a low melting point, which enables its easy use in the injection moulding process and 3D printing. It also has high tensile strength and is very resistant to physical impacts and chemical corrosion, which allow the finished plastic to withstand heavy use and adverse environmental conditions.
• High dimensional stability (Mechanically strong and stable over time)
• High surface brightness and excellent surface aspect.

Wher it is used?

• It is used in the rear side of the car at the bottom surface. This is used to protect the body of the car for unexpected damage.

Followed Constrains:

• The change in dimension of the Class A Surafce is not allowed.
• Change in thickness is not allowed.
• The thickness given to the Bumper is 3 mm.

Tooling Axis:

• The tooling axis for this component will be created from x component. This shoud be done using the method of extracting the plane surface and Creating a point in the plane using point on the surface. And fiinally the line shoud create using the normal to surface.

Class A Surface:

• Class A Surfaxce is a scaned model or the model which is already drawn is given for further process. It describes the final production surface data for the aesthetic parts of the car. The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modeling. This is the outer layer of model.
• Class A surface is created from the igs part file. We have to join the model in file to create a class A surface.

Draft Analysis:

• The draft analysis technique is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied. Here the part should get easily removed from the panel dies (in case of Sheet metal part) or Mold (in case of plastic). The analyse shows whther the angle given in the surface is upto the level or not. This can be identify by using the Green, Blue and Colour. Green means to perfect (< 2.9deg), Blue (0deg), Red (> 2.9deg).

DRAFT ANALYSIS OF CLASS A SURFACE

DRAFT ANALYSIS OF OVERALL SURFACE

Class B Surface:

• This is the surface followed by Class A Surface. It is the inner surface of the model with some thickness. The fillet and offset of the Surface shoud given according to the Class A model. The flash from the molding process shoud not come in the surface of the Class A, so the Class B design shoud not distrub the class A Surface.

• We have to create overall offset for this bumper. After this we need to multi extract the line in 3 different portion namely License palte, Grill part and Outter top bumper surface. We have to give curvater for the extrapolate for easy fillet operation.

Class C Surface:

• Class C Surface is the surafce which join both the class A & B uisng the boundary, trim, join method. The Class C finish allows more imperfections than Class A or B. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces which the Customer feels do not need to meet a high cosmetic.

• This Class C Surface is taken from the Reference of the Class A Surface. with the angel of 90 deg for the both Outter bumper surface and license plate surface. And the grill part should required 3 deg sweep for that surface.

Final Product:

• Final product includes the finished surface of Class A, Class B and Class C. Having the complete surface model of the Bumper .

Join A & C

FINAL TRIM

Solid Surface:

• After the completion of the final trim it shoud be change to the Close surface.

FINAL OUTPUT

MULTI VIEW

FAMILY TREE