Week 9 - Challenge 3 - Bumper
BUMPER DESIGN
AIM
To create the BUMPER plastic component from the given Class A Surface as an input.
CLASS A SURFACE GIVEN AS INPUT
There are following steps, which have to perform by using Class A Surface:-
- First understanding the CLASS A SURFACE.
- Than creating the TOOLING AXIS.
- Draft analysis 1 for CLASS A SURFACE.
- Creating geometrical sets for CLASS B SURFACE.
- Creating CLASS C SURFACE using boundary and sweep command.
- FINAL TRIM to get Final Surface.
- Than go to PART DESIGN to get Close Surface Body.
- Draft analysis 2 for CLOSE SURFACE BODY.
1. First understanding the CLASS A SURFACE.
- Class A Surface is given as an input for product design.
- Class A Surface is thickened by using engineering features.
- The part which is obtaining after Class A Surface get thickened are use for manufacturing in real time application.
- The Boundary Condition of Class A Surface must be checked.
2. CREATING THE TOOLING AXIS
- From Class A Surface, we have to form TOOLING AXIS.
- The point where the component get molded from injection molding.
- On that point, create POINT first using EXTRACT surface.
- On that point, using point direction to form tooling axis.
3. DRAFT ANALYSIS 1 FOR CLASS A SURFACE
- Draft Analysis technique is used to analyse the product which we design is manufacturable and prevent the part being parallel to the direction of mold opening.
- The product can not be manufacturable, if it has 90° profile, which is parallel to the TOOLING AXIS.
- A small draft angle is applied in order to remove the component from the mold.
- No part is manufacture without the draft angle.
DRAFT ANALYSIS FOR CLASS A SURFACE
ISOMETRIC VIEW
FRONT VIEW
SIDE VIEW
TOP VIEW
- The green colour represent the draft angle is upto 3°.
- The red colour represent the draft angle is 0°.
- The blue colour represent the draft angle is in negative side.
4. Creating geometrical sets for CLASS B SURFACE
- THICKNESS 3 mm is given as input.
- The CLASS B SURFACE is obtained from CLASS A SURFACE on giving offset with thickness 3 mm.
- During offset, some flaws shows so this flaws are now recreated by using EXTRACT COMMAND .
- And complete all patches one by one where flaws shown.
- And after completing all patches then use fillet to get proper fillet using thickness properties.
ISOMETRIC VIEW
FRONT VIEW
SIDE VIEW
TOP VIEW
THE OFFSET VALUE FOR FILLET SIZE :-
- THICKNESS + RADIUS = OFFSET INSIDE THE CLASS A
- THICKNESS - RADIUS = OFFSET OUTSIDE THE CLASS A
5. CREATING CLASS C COMPONENT
- The CLASS C SURFACE is the final output obtained from the CLASS A and CLASS B Surface.
- Using boundary of CLASS A SURFACE and sweep the boundary with draft value 3° and also with taking reference surface 90°
- The CLASS C SURFACE has the thickness 3 mm and draft value as per requirement provided.
- The CLASS A and CLASS C SURFACE are JOIN and TRIM with CLASS B SURFACE to form the final BUMPER SURFACE
CLASS A + CLASS B + CLASS C = FINAL PRODUCT WITHOUT TRIM
6. AFTER FINAL TRIM SO FINAL BUMPER SURFACE OBTAINED
- The CLASS A and CLASS C SURFACE are JOIN and TRIM with CLASS B SURFACE to form the final BUMPER SURFACE.
7. GO TO PART DESIGN TO GET CLOSE SURFACE BODY
ISOMETRIC VIEW
FRONT VIEW
SIDE VIEW
TOP VIEW
8. DRAFT ANALYSIS 2 FOR BUMPER FINAL CLOSE BODY
ISOMETRIC VIEW
FRONT VIEW
SIDE VIEW
TOP VIEW
- The green colour represent the draft angle is upto 3°.
- The red colour represent the draft angle is 0°.
- The blue colour represent the draft angle is in negative side.
TREE STRUCTURE OF CLASS A AND TOOLING AXIS
TREE STRUCTURE OF CLASS B
TREE STRUCTURE OF CLASS C
TREE STRUCTURE OF FINAL TRIM
TREE STRUCTURE OF BUMPER CLOSE BODY AND DRAFT ANALYSIS AND PUBLICATION
