Week 9 - Challenge 3 - Bumper

Aim: To develope a solid plastic part of a car bumper from the given Class-A surface.

Procedure:

Creation of Tooling Axis:

1. From the given class-A surface, a flat surface is extracted and a point is created on the extracted flat surface.
2. From visual analysing the class-A surface,a line is drawn from the point  to the suitable tooling axis direction.
3. In this given class-A surface,the suitable tooling direction is in x- direction.

Creation of Draft Analysis:

1. A draft analysis is done by clicking Insert>Analysis>Feature Draft Analysis.
2. Draft Value is given as 3 degree.
3. Compass is selected and made coincidence with tooling axis and locked.
4. Class-A surface is selected and thus draft analysis is generated.

Creation of Class-B surface:

1. The class-B surface is generated by offsetting the class-A surface to the required thickness i.e., 3 mm.
2. The offsetted surface has some gaps as a result of fillets in class-A surface.
3. These gaps are cleared using multi section solid , extract, boundary, extrapolate and trim commands.
4. After clearing the gaps,all the objects is joined to the class-B surface using join command.

Class-B surface with gaps:

Finished Class-B surface:

Creation of Class-C surface:

1. The Class-C surface is generated by sweeping the class-A along the draft direction.
2. The swept surfaces are checked to ensure complete sweep surface is formed.

Final Model:

1. Class-A,Class-B,Class-C surface are trimmed and Joined using trim and join commands respectively.
2. Using the close surface command the final model is made into a part model.

 Half Bumper:

Full Bumper: