Week 8 - Challenge 4 - Bumper

OBEJECTIVE:

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

Commands used mostly are Extract, Multiple Extract, Untrim, Join, Trim, Extrapolate, Offset.

PROCEDURE STEPS:

1. Check the given Class A surace is Closed or Open surface by using Boundary command
2. Craete the Tooling axis with the help of side wall surfaces.
3. Draft analysis is carried out for given Class A surface wheather it is feasable or not for Draft Angle 3 Deg.
4. Create the Class B surface using the Class A surface at a Offset distance of 3.0mm (Thickness of component is 3.0mm)
5. Give the Fillets values to the edges that arre on the class A surface with respect to the thickness of component is 3.0mm
6. Create Class C surface that connects the Class A and Class B surfaces by using sweep command with reference of Class A surface.
7. Join the Class A surface and Class C surface and then Trim with Class B surface.
8. Check wheater it is a closed surface or not , by using the Boundary command.
9. Create a Closed Part Body by using the Closed Surface command in Part Body Design.
10. Do the Draft analysis for the Closed Part Body with the help of Tooling Axis , then it should clear the both Core side and Cavity side and the Draft angle should be minimum 3Deg.

PROCEDURE:

1. Checking the given Class A Surface.

• Checked the Class A surface is a Closed profile by using the Boundary command.
• The complete profile has only one Boundary at the outer edge without breakage.

2. TOOLING AXIS & DRAFT ANALYSIS

• Analyised the given Class A surface of all Posibilites of Direction.
• Confirming the Possible direction for the tooling direction as most of the surfaces of Class A are Visible.
• Created a mid point in base plane and draw a line along the possible direction as a Dummy Tooling Axis.
• Check the Dummy Tooling Axis as it clears the Core & Cavity at Draft Analysis for 3Deg.
• The Line that clears the Draft Analysis is the Tooling Axis.

X-Direction

Y-Direction

Z-Direction

• The Possible Direction is X-Direction.

3. DRAFT ANALYSIS of CLASS A SURFACE:

Draft analysis is carried out to check wheather given Class A Surface is feasable or not for creating Plastic Component.

• Select the Draft Analysis to the Class A Surface.
• Select the Axis and place the Axis line along the Tooling Axis direction.
• Select the Draft angle degree as 3Deg minimum.
• Selected the Surface and found in Green Colour in all the surface area
• Cross checked the angle of draft at all surfaces and found that is more than 3 deg.

4. Creating Class B Surface:

Class B surface is mostly the not visible surface and it is the back of the Class A surface.

• Offset the Class A surface for 3mm (Thickness of Component is 3mm).
• The offset surface has the Patches that the minimum fillet value placess cant be offset.
• The Patched surfaces are Extarcted by using the Extract & Multi Extract Commands
• Then the Surfaces are Extrapolated untill the Intersection done
• Then the both Surfaces are Trimed by using Trim command.
• All the surfaces are Checked for the patches.
• Cross checked gap between the two surfaces found that to be 3.0 mm.

Patched Surfaces

Class B Surface

5. Fillets:

• The finished surface is given the Fillet vallues.
• The thickness should be added or subtracted to the fillet value based on the direction of it.
• Checked the remaning surfaces that all are filleted and no sharpeges found.
• To find the Radius of the Surface is create an arc on the boundary of surface and mesure the radius by creating the circle arc on the outer profile.
• The minimum fillet radius is given that 0.5mm.

.

Creating an Arc on the boundary.

6. Class C Surface:

Class C Surface is that connect the Class A Surface and Class B Surface.

• Create a boundary on the Class A surface at the individual corner and then Sweep it individually.
• By using the Sweep Command with the reference of Class A surface and angle of 90Deg to it.
• Then the individual surfaces are Joined by using the Join Command.
• The thickness or length of the Class C Surface is 4mm minimum so that it will be trimed easily.

Class C Surface

7. Class A and C surface:

• Class A surface and Class C Surface are joined by using the Join Command.
• Class B surface is Extrapolated at its Boundry for the trim
• Now the Joined Class A & C Surace is trimmed with the Class B surface.

Class A & C surfaces are Joined.

Class B surface Extrapolated

8 & 9 Closed Surface:

• The Trimed surface is formed.
• Created a boundary on the Trimed Surface so that it inssures that no boundary formed.
• Confirms that it is completely closed.
• By using the Closed surface Command in the Part Body Design to the surface body.
• Now the Solid Body is formed.

10. DRAFT ANALYSIS:

• Select the Draft Analysis to the ClOSED SURFACE.
• Select the Axis and place the Axis line along the Tooling Axis direction.
• Select the Draft angle degree as 3Deg minimum.
• Selected the Surface and found in Green Colour in all the surface area in the Draft Direction.
• Checked the inversion of Drafting to the Core side and Cavity side.
• Cross checked the angle of draft at all surfaces and found that is more than 3 deg.
• The Parllel surface that of Class C suraface are having the Draft angle of 1.5deg and the surafce area is minimal and it will not interupt it.

Draft Analysis Closed Body.

Here Attached the Tree Structure of Component and Methods followed.

TREE STRUCTURE

Conclusion:

This is the method I followed and Here I attached the Different views of the Created Part Body.

Different Views

Isometric View

Front View

Back View

Left View

Right View

Bottom View