Week 8 - Challenge 4 - Bumper
BUMPER DESIGN
TOOLING AXIS : Tooling axis means the direction in which core and cavity open and close.Tool is nothing burt mold, tooling axis is created to know in which direction the mold open and close, parts drafts are given along this axis.
MATERIAL SELECTION FOR COIN HOLDER AND REASON FOR SELECTING THAT PARTICULAR MATERIAL :
Bumpers of most modern automobiles have been made of a combination of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) called PC/ABS. This material has high strength, high stiffness, high heat resistance, and high impact resistance, even at low temperatures. PC-ABS retains its dimensional stability over time and its enhanced flow characteristics and processability make it easy to work with.
MANUFACTURING PROCEDURE :
Injection Molding
It is a manufacturing process used for the mass production of plastic components. It works by injecting molten material(plastic) into a mold. Under the application of heat and pressure, the material solidifies into the required shape. Once the product cools, it is ejected from the mold with the help of ejector pins.
DRAFT ANALYSIS : Draft analysis is done to check weather the tooling axis and draft angle are correct or not and to find weather the component is manufactured and ejected or not. Draft Analysis is a tool in CATIA which identifies the zones which deviates from the specified values of angles along a defined draft direction using colour codes.
DRAFT ANALYSIS 1
DRAFT ANALYSIS 2
CLASS A SURFACE : Asurface is the aesthetic surface created by the class-A engineer. It is the visible aesthetic surface of any automotive component. class A surface is any of a set of freeform surfaces of high efficiency and quality.
CLASS B SURFACE : B surface is the offset of the class A surface. Class B surfaces are Engineering Surfaces which are invisible to the eyes or often on the back side of the Class A surfaces. It is mainly the thickness of the component or Class A.
CLASS C SURFACE : C surface is joining surface between A and C. Class C surfaces are connectors between Class A and B surfaces. This surface connects both A and B surfaces along the Tooling Axis. It contains the draft as per the design. Its is basically the thickened surface between both A and B surface.
CLOSED SURFACE BODY
SOLID BODY
CONCLUSION
This project imparted a great deal of knowledge regarding the creation of tooling axis and performing proper draft analysis on a component which are essential steps to ensure a design is fit for manufacture. It also provided valuable insights on the design of a plastic component using Class A, B and C surfaces using CATIA.