Challenge

Week 9 - Challenge 3 - Bumper

VVeeralekshmanan K11 May 2023

Week 9 - Challenge 3 - Bumper

Aim:

To Create the Bumper Plastic component through the given Class-A surface and create 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 solid model.

Objective:

Create the required tooling axis
create B & c surface
Create close surface
draft analysis the Class A and Final Component.

Tooling Axis:

In plastic design injection molding the Tooling Axis is the most important criteria. The tooling axis tends to the core and cavity area, also the component ejecting direction of the core and cavity is most common in tooling direction only. For creating the tooling axis in this bumber challenge is differnt and very ease with comparing to the previous plastic component design.

Here first created the point the option of point on curve to the class A surface and select the middle point.

Then create the line to the line command at the point - direction type with the reference of paralel to the Claas A surface that is X diection.

Then analys the class A surface with this tooling axis,the class A surface is passed the the draft analysis we can proceed with this same as a tooling axis for creating Class B and C surface.

Class A Surface:

Class A surface is the aesthetic skin data for the automotive part designing and curvature surface to represent the main component.Befor proceed with A surface to analys the Draft angle, if get any mis-match surface reconstruct the A surface.

Draft Analysis Class A

Draft analysis is the main requirments in plastics Design. If the draft angle is less than 0 degree, the part or component and tool is to be damaged in mass production. Also the molding part would not eject from the core and cavity. So the drafting analysis to find out the lesser angle are by the colour variation.

Above 3 - Green

0 to 3 - Blue

< 0 - RED

Class B surface:

In this pumber challenge Class B surface also creating new method comparing with previous challenge. Here we directly offset the class A surface to the total thickness of close body to inward direction.

Thickness of the component to be 3 mm

So offset the class A to 3 mm inward, inthis case fillets are showing some error. Because of the inward offset the fillet will be reduce.At this moment we reconstruct the B surface with respect to the A surface.

So using multiple extract command and extract the surface which is in the missing fillet area. Then spilt from the offset.1 and using join with the option of sub element to remove to remove the fillets and extracted surface from the offset.1.

Then trim with the removed surface got the b surface and give the all fillets with respect to class A.(Here consider the offset is inward direction so the fillet radius will change with respect to the thickness of close surface.)

Class C surface:

For creating the C surface draw a boundary to the class surface edges and sweep the edges with draft direction and with reference surface. The surface which is paralel to the tooling axis to use the sweep at the draft direction and the surface which is perpendicular to the tooling axis is swept with the reference surface.

Then extrapolate the missing edges and trim together wil get the class C surface.

Class A and Class C:

To join the class A and Class C surface by using joint command.

Final Trim:

To trim the Surface (A+C ) with the B surface.

Close Solid Surface:

START -> MECHANICAL DESIGN -> PART DESIGN -> SURFACE FEATURE -> CLOSE SURFACE

Front View:

Side View:

TopView:

Iso View:

Final Close Body Draft Analysis:

The final draft analysis the close surface clear by the draft angle.Here 3 degree is the minimum draft angle to drafted over the area which is permissible at the injection molding manufacturing area.So the draft analysis was done successfully.