Week 9 - Challenge 3 - Bumper

REPORT :

• Aim : To create a Switch Bezel Plastic Component through a given Class A Surface and perform Draft Analysis on the final plastic component.

• Objectives :

  • Creation of Tooling Axis.
  • Creation of Class B and Class C surface.
  • Creating a solid part out of surface modelling.
  • Draft Analysis of Class A surface and final plastic component.

• Introduction : In this project we are designing a Bumper using given Class A surface. The approach includes creation of Class B surface keeping 3 mm thickness in mind for the complete component. The design also included Class C creation from the given parent surface.

Constraints :

• NO CHANGES IN CLASS A ARE ALLOWED.
• ALL DESIGN RULES SHOULD BE STRICTLY FOLLOWED.
• ALL SURFACES SHOULD BE CLOSED BEFORE CONVERTING TO SOLID.
• ALL FACES SHOULD MEET THE ALLOWED DRAFT REQUIREMENTS.

CLASS A : Following surface is given as the input for the component creation.

• Creation of Tooling Axis : The tooling axis is not created with bisecting method because of the complex geometry of Class A Surface. The dummy tooling axis is considered as main Tooling Axis.

• Draft Analysis for Surface A : The analysis is done for 3degree draft. So as can be seen all the surfaces are more than 3deg.

• Creation of Class B :

  • Now for Class B creation, we have do the direct offset method.
  • These surfaces are then offset to the required thickness but there are some missing patches.
  • After offsetting, all the missing patches are done by boundary, extrapolate & trim method.
  • Required fillets are given to the surfaces.

• Creation of Class C Surface :

  • For creating this surface we have created the boundry of Class A using Boundary Tool.
  • Now this boundary curve is swept along the draft direction with a 3deg draft.
  • Then some portion etrapolate & trim where needed.

• Class A + Class C :

  To make sure that there is not any open boundry between class A and class C, we have used join option to created the single body. This is done to make sure that the parting line doesn't lie between the these two surfaces.

• Class A + Class B + Class C :

  For this we have trimmed the above shown surface with the Class B surface using trim feature.

All the main features are published as can be seen in the image shown above.

• Close Surface : We perform a close surface operaration to ensure that there is no open boundary of the final product of the Bumper.

• Draft Analysis on the Final Product : For this analysis, main tooling axis is taken draft reference. Following results were obtained.

• Isometric View :

• Front View :

• Side View :

• Top View :