Challenge

Week 9 - Challenge 3 - Bumper

REPORT ON BUMPER DESIGN

STEPS TAKEN TO CREATE THE BUMPER DESIGN ARE AS FOLLOWS:-

1.INPUTS-

HERE WE WILL RECEIVE THE CLASS A SURFACE AS AN INPUT.
USING CLASS A SURFACE WE HAVE TO FORM CLASS B AND C SURFACES TO FORM A FINAL PLASTIC COMPONENT AS SHOWN IN BELOW FIGURE.

2.TOOLING AXIS-

TO CREATE AN TOOLING AXIS WE HAVE TO CHECK WHEATHER ALL THE FACES OF CLASS A SURFACE IS VISIBLE IN AN PARTICULAR DIRECTIONS OR NOT.
ALONG X DIRECTION ALL THE FACES OF AN CLASS A SURFACE IS VISIBLE SO THE TOOLING AXIS CAN BE FORMED ALONG THE X DIRECTION OR AXIS AS SHOWN IN BELOW FIGURE.

HERE WE HAVE TO CREATE A POINT ON A CURVE AND CREATE A LINE ALONG X AXIS TO FORM A DUMMY TOOLING AXIS WHICH IS AS SHOWN IN BELOW FIGURE.

3.DRAFT ANALYSIS ON CLASS A SURFACE-

DRAFT ANALYSIS IS DONE TO ANALYSE WHEATHER THE SURFACE CAN BE CLEARED IN CAVITY SIDE OR NOT.
IF THE CLASS A SURFACE GETS CLEARED THEN THE DUMMY TOOLING AXIS WILL BE THE MAIN TOOLING AXIS OF THE COMPONENT.
HERE SELECT THE COMPASS AND PLACE IT ON THE TOOLING AXIS AND LOCK IT, THEN SELECT THE CLASS A SURFACE WHICH INDICATE THE DRAFT ANALYSIS IN THE FORM OF COLOUR CODES.
THE CLASS A SURFACE DRAFT ANALYSIS ARE AS SHOWN IN BELOW IMAGE.

4.BUMPER DESIGN-

A.CLASS B SURFACE FORMATION-

INITIALLY OFFSET THE CLASS A SURFACE FOR 3MM TO GET AN CLASS B SURFACE, AS THE CLASS A GEOMETRY IS COMPLEX SOME OF THE ELEMENTS OR FILLETS WILL BE LOST WHICH ARE SHOWN IN BELOW FIGURE.

SO WORKING ON THESE MISSING ELEMENTS AND FILLETS THE CLASS B SURFACE WILL BE FORMED AS SHOWN IN BELOW FIGURE.
THE OPERATIONS WHICH ARE USED TO CREATE AN CLASS B SURFACES ARE AS SHOWN IN THE TREE STRUCTURE AT THE LAST STEP IN BUMPER DESIGN.

B.CLASS C SURFACE FORMATION-

TO CONSTRUCT THE CLASS C SURFACE WE HAVE TO ANALYSE WHEATHER THE SURFACE TO BE FORMED IS PARALLEL OR PERPENDICULAR TO THE TOOLING AXIS.
IF THE SURFACE TO BE FORMED IS PARALLEL TO THE TOOLING AXIS THEN MINIMUM OF 3 DEGREE DRAFT IS TO BE PROVIDED.
IF THE SURFACE TO BE FORMED IS PERPENDICULAR TO THE TOOLING AXIS THEN NO NEED TO PROVIDE AN DRAFT ANGLES AS THE SURFACE IS 90 DEGREE TO TOOLING AXIS IT CAN BE EASILY CLEARED IN CAVITY SIDE AND ALL THE SURFACES NEED TO BE TRIMMED TO FORM A SINGLE UNIT WHICH IS AS SHOWN IN BELOW FIGURE.

C.FINAL TRIM-

TO GET AN FINAL PLASTIC COMPONENT TRIM THE JOINED CLASS A AND CLASS C SURFACE WITH CLASS B SURFACE AS SHOWN IN BELOW FIGURE.

D.CONVERTING INTO CLOSE SURFACE-

FIRSTLY WE HAVE TO SWITCH TO THE PART WORKBENCH THEN DEFINE IN A PART BODY AND SELECT THE CLOSE SURFACE TOOL TO CONVERT INTO A FINAL SOLID COMPONENT AS SHOWN IN BELOW FIGURE.

5.DRAFT ANALYSIS ON THE FINAL SOLID COMPONENT-

SELECT THE DRAFT ANALYSIS TOOL, USE COMPASS TO PLACE IT ON THE TOOLING AXIS AND LOCK THE COMPASS AND THEN SELECT THE COMPONENT TO INDICATE THE DRAFT ANALYSIS IN THE FORM OF COLOUR CODES.
THE DRAFT ANALYSIS IN THE FORM OF COLOUR CODES ALONG VARIOUS VIEWS ARE AS SHOWN IN BELOW FIGURE.

6.EXPANDED TREE STRUCTURE AND PUBLICATIONS-

Ship work like this
in your own course.