Week 8 - Challenge 4 - Bumper

AIM

To create the Bumper Plastic component through the given Class-A surface.

REPORT

1. Creation of tooling axis

• First we check the connectivity of the given class A surface using boundary or join command. 
• We study the surface at all axis and decide on the best possible side to create tooling axis.
• First, let us extract a small surface from class A through which the tooling axis passes.
• Create a point on the extracted surface at its center.
• Create a dummy tooling axis passing through the point along x axis.
• Create a plane normal to curve.
• Select the intersection option and create an intersection on class A with the plane.
• Once the intersection is created, identify the two surfaces which are problmatic while tooling.
• Draw line on both these surfaces using line command.
• Again using the bisecting lines in the line command, a new line is formed which is our tooling axis.

2. Draft analysis on Class A surface

• Once the tooling axis is created, we conduct draft analysis on the class A to verify thr tooling axis.
• Click on thr draft analysis icon.
• Select the compass and place it on the tooling axis.
• Click anywhere on the surface, draft analysis occurs.
• From the results we can see that its completely in green colour.
• This means that there is a positive draft of 3 degrees which is good.

3. Creation of B surface

• First, offset the A surface inwards by 3mm.
• We can see lot of patches in the offseted surface.

Patch 1

Patch 2

Patch 3

• So we try to fix all those patches one by one.
• Lets take patch one.
• Using multiple extract we extract all the patchy surfaces using complimentary mode.
• Then again using multiple extract, we extract the outer surface which we require to connect it to the main surface.
• Using the extrapolation option we extrapolate the extracted surface to a certain distance.
• Then we extrapolate the main body till it intersects the above extracted surface.
• Using trim we trim the unwanted surface and gets the patchy surface repaired.
• We then apply edge fillets on them.

• For fixing patch 2, we extract the patchy surfaces.
• Unrim these surfaces.
• Extrapolate them till they intersect.
• Trim all of them.
• Extrapolate the main body till it intersect the above body
• Trim these two surfaces and apply edge fillet to repair these patches.

• Similarly what we have done for patch 1, same steps are repeated for patch 3 to form the B surface.

B surface -

4. Creation of C surface

• To create C surface, we take boundary from one sharp corner to another.
• Apply sweep command with reference surface.
• Almost 7 sweeps are created.
• All those sweeps are extrapolated and trimmed to form a single surface.
• Similarly we apply sweep to the inner section also.

5. Final Join

• Join Class A and C surfaces together.
• Extrapolate the boundaries of B surface.
• Trim the A+C surface together with B surface.

6. Closed surface/Final component

• Open part design.
• Select closed surface option and apply it on the final join.

7. Draft analysis on Final component

• Repeat the same steps for draft analysis as done on Class A.
• We can see green for core side and red for cavity.
• Hence it passes the analysis.

RESULTS

1. ISOMETRIC VIEW

2. FRONT VIEW

3. SIDE VIEW

4. TOP VIEW