Week 8 - Challenge 4 - Bumper

Objective:

The main objective of this challenge is to create a solid body of 'Bumper' with the help of the closed surface method by using the 'Generative shape design' workbench in CATIA. Performing the 'Draft Analysis' on the solid part body of the Bumper.

Overview:
Initially, we need to offset the given Bumper class A surface in the inner direction to the required thickness (here the thickness is 3mm). After that, we need to close the patches on the offset surface of the bumper, the patches are formed due to the fillets on the Class A surface. Once all the patches are closed properly join them together to make a proper class B surface and now sweep the boundary of the class A surface to trim with the class B surface to make a closed body. By using the closed body command in the Part workbench we can get the solid body from the closed surface of the Bumper. Now, again went back to the surface workbench to perform the 'Draft analysis' for the solid body.

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.

CLASS B SURFACE:

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 3mm). 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 extrapolate and trim option. 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 surface.

CLASS C SURFACE:

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 90deg for 5mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweeped 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.

PART BODY:

To create the solid part body from the closed surface, I used the closed surface command in the part workbench.

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