Week 8 - Challenge 4 - Bumper

Aim:

  To Create the Bumper Plastic component through the given Class-A surface with 3 mm thickness

Tooling axis:

   To create the tooling axis, I extracted a surface from class A and created a point in the middle of the surface by using the point command and created a line at that point through the x-axis. Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not. If, in the draft analysis check the surface highlighted with green colour on both sides of the surface the tooling axis is in the correct position and direction. 

Draft analysis:

     First we analysis the model and then choose dummy axis in x and y direction.
As we intersect, we observed that the side walls are not given any draft. Hence, we assume the axis normal to the base surface and parallel to side walls. This surely will create problems because a minimum draft has to be provided.

DRAFT ON PART-

DRAFT ON CLASS A-

Class B:

       To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 3mm, so I offset the class A to 3mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multi-section surfaces command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface. 

Class C:

    To create the class C surface concerning the boundary of the class A surface, I used the sweep command. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweep surfaces until both surfaces got intersected properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the centre hole of the bumper. 
Now, join both class A and sweep boundary to get the complete class C surface. 

Final join:

    Now, unhide the class B and class C surfaces. Check whether all the sides of class B and Class C surfaces are intersecting properly with each other, to get a closed surface by trimming class B and class C surfaces. If the class B and class C sides are not intersected properly, we need to extrapolate the sides of the class B surface which are not intersecting with the class C surface. Now, check class B and class C surface boundaries whether all the sides are intersecting or not with each other. Once the surfaces are intersecting properly trim them together to get a closed surface. 

ISO VIEW-

FRONT VIEW-

SIDE VIEW-

TOP VIEW-

GENERAL NOTE:I changed netral clour blue to red