Challenge

Week 8 - Challenge 4 - Bumper

AAditya Raj16 Jan 2023

Week 8 - Challenge 4 - Bumper

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.

Take the Thickness of the component to be 3 mm

CLASS A-SURFACE-

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 OF CLASS-A-SURFACE-

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 analysis is done on the Class A Surface with respect to the Tooling Axis created.

Minimum draft angle will be 3 degree.

B-SURFACE-

Class B was created by offsetting class A to the thickness of the component, (i.e.) 3 mm. And the improper patches are repaired. the commands used are Multiple Extract, Extrapolate, Trim, Edge Fillet, Surface Fillet, and Join. The Areas where the B-surface has issues are corrected by closing them using commands like Multi section,Sweep,Offset and extract.Finally all the created surfaces are trimmed or joined together with offset surfaces done earlier. This created a single single surface which will act as the final B-surface.

C-SURFACE-

Multiple boundaries are created on the Class A Surface using Multiple Extract Command and a sweep was done with each of the boundaries as a guiding curve and Class A Surface as a reference surface at 90 degrees. Those sweeps are then joined with the Class A Surface to form C Surface.

JOIN (A+C) & TRIM B-SURFACE-

All the surfaces (A+C) are joined together and trim the B surface to form a closed body.

Boundary is selected and the body is picked. Since an error popped up it can be understood that all surfaces are joined with each other to form a proper closed surface body.

Finally in part design workbench, using close volume it is changed to a solid body.

AND USE MIRROR COMMAND WITH RESPECT TO YZ PLANE TO CREATE FULL BUMPER.

SOLID BODY-

DRAFT ANALYSIS-

The final solid part body has to be analyzed using Draft analysis. This is done to check if all the areas of the body are satisfying the draft angle which is 3 degrees.

A draft angle is a taper applied to the vertical walls of the injection-molded component to assist with releasing the part from the mold.

Draft angles are a required feature of injection-molded custom parts. A functional part for injection molding has to have draft angles that face both the cavity and core sides. This will reduce the risk of damage to the parts and ensure that they can be ejected from the machine.

The Bumper body is checked using Analysis and images for it are shown below.