Week 8 - Challenge 4 - Bumper

AIM:

To 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.

A SURFACE:

The A-surface or the styling surface is first checked for any gaps and other issues in its surfaces. This Surface acts as the input surface so any correction to be done should be with approval from the styling team or done by them. A- perfect surface is the one when a boundary is created.

CREATION OF TOOLING AXIS:

Tooling axis is the direction in which a core or cavity of mold opens. This Axis is very important to determine the orientation of the component in mold, core and cavity design.

The tooling axis is created by the inertia method by using the steps as follow

• Click “Measure inertia” and select the A-surface

• Click “Create geometry” in the Measure Inertia window.

• In the Creation of Geometry window, select Non-associative geometry.

• Click “Center of Gravity”

• The Inertia point is created.

• The component is viewed in all axes namely X,Y and Z.

• It is determined that the X-axis will be the direction for the Tooling axis and a line is created Using the CG point and X-direction as direction of the line.

CREATION OF B-SURFACE:

The A-surface is offsetted by 3.00mm as it is the thickness required.

The offset surface is the B-surface but had some issues. 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.

CREATION OF C-SURFACE :

• The A and B surfaces are connected by another single surface which is called the C surface.
• It is created by using sweep with A surface acting as the reference surface and curve created from the boundary of the same surface.
• Sweep with draft direction is also used to create A-surfaces.
• All the surfaces (A,B,C) are joined together 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.

CLOSED PART BODY:

DRAFT ANALYSIS OF A SURFACE:

Draft analysis of the surface is carried to check if the surface or part can be manufactured with the required draft angle.

Draft angle is needed for the component to clear the core and cavity surface as it would have shrunk towards the center while cooling.

The draft angle in this design is 3 degrees. As A surface is a single surface there won't be much difference in color.

DRAFT ANALYSIS OF PART BODY:

• 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.

ISOMENTRIC VIEW:

FRONT VIEW:

TOP VIEW:

SIDE VIEW: