Week 9 - Challenge 3 - Bumper

  BUMPER WORKBENCH

Objectives: To create BUMPER COMPONENT model using the Class-A Surface. It’s a plastic component so by keeping in mind all engineering constraints the model will be designed. This starts with the TOOLING AXIS for the Class-A surface should be create.

Introduction:

Class-A Surface: It is an outermost surface which is developed by the designers and it is provided as an input to the modeller to work on it.

Class-B Surface: It is a surface at a certain thickness from the Class-A Surface.

Class-C Surface: It is a surface that joins the Class-A and Class-B Surfaces.

 

Commands or tools were used to create a closed surface/solid model, performing on the Class-A surface: 

OFFSET >> MULTIPLE EXTRACT >> BOUNDARY >> EXTRAPOLATE >> SPLIT >> TRIM >> EDGE FILLET >> UN-TRIM >> SWEEP >> JOIN >> CLOSED SURFACE (Part Design) >> DRAFT ANALYSIS

Orientation Views:- Front, Side, Top and Isometric views.

FOR TOOLING AXIS CREATION:

• First with the point command center is created from Class-A surface for creating a dummy tooling axis.
• Now creating a dummy tooling line along X-axis direction with the line command.
• Finally TOOLING AXIS line with the line command is created.

FOR CLASS-B SURFACE CREATION:

First we directly offset the Class-A surface for creating Class-B surface which is of 3mm in distance. The previous methods can’t use cause for simple components the methods are easy to create any component but complex component like bumper which is not easy to create those methods are not applicable. After the offset of Class-A surface, it can be seen that on Class-B surface some of the patches are missing. So for that all the missing patches should be filled below are the processes for filling the patches.

UPPER GRILL SURFACE CREATION:

• By using multiple extract command creating two different surfaces to achieve a sharp edge between them.
• When second surface is creating there are lot of small patches, so only the removal patches are selected and now activate the complementary mode from multiple extract interface. It can be seen that the selection is reversed and click OK.
• Now two different surfaces are created but it is not trim-able because there are not intersecting.
• By using boundary command on the first surface edge creating a continuous boundary line.
• Now with the extrapolate command an extended surface is created.
• Same process will be done for the second surface.
• Now with the trim command both the surfaces are trimming to achieve a sharp edge, the missing patches or gaps are removed with well finish edge.

MIDDLE GRILL SURFACE CREATION:

• By using split and join commands two different surfaces are going to create.
• First with the multiple extract command created a cutting element path for split command.
• Now by using split command created the first surface.
• Now second surface is created with the join command using sub-elements to remove.
• Now both the surfaces are extrapolated one by one for surface extension.
• Both the surfaces are trimmed with the trim command and finally the required surface is achieved.

NUMBER PLATE SURFACE CREATION:

• In this section again creating two different surfaces by using join command and removing those surfaces which are not required.
• Now with the multiple extract command number plate surface section is created because after using join command still it is in single output.
• Again with the multiple extract command the number plate surface is removed.
• By using join command the number plate surface again segregated in two different surfaces and then extract, un-trim, extrapolate and trim commands are used to bring the number plate surface as a single output.
• Now extrapolated the second surface.
• Finally both the achieved surfaces are trimmed with the trim command to get the final output surface.

FINAL CLASS-B SURFACE CREATION:

• Finally by providing fillets on the achieved trimmed surface Class-B Surface is created.

FOR CLASS-C SURFACE CREATION:

MIDDLE GRILL SURFACE CREATION:

• It is seen that middle grill surface is perpendicular to the tooling axis, so with the sweep command the extended surface is going to create.
• First by using boundary command creating a path for sweep.
• Now creating an extended surface with the sweep command by using ‘with draft direction’.

 OUTER BOUNDARY SURFACE CREATION:

• With respect to tooling axis outer boundary surface is parallel to it.
• By using boundary command creating a path for sweep.
• Now creating an extended surface with the sweep command by using ‘with reference surface’.

RH & LH FOG LAMP SURFACE CREATION:

• With respect to tooling axis RH fog lamp surface is parallel to it.
• By using boundary command creating a path for sweep.
• Now creating an extended surface with the sweep command by using ‘with reference surface’.
• Applying the same process for the LH fog lamp surface.

FINAL BUMPER SURFACE CREATION:

• Now with join command, join the Class-A and Class-C surfaces.
• After joining of Class-A & Class-C surfaces trim the achieved surface with the Class-B surface.
• Finally the closed surface body of the component is achieved in the surface design.
• Now move to part design with the close surface command, solidifying the component.

FOR DRAFT ANALYSIS CREATION:

• First set material mode, now click on the draft analysis.
• After opening an interface of draft analysis, click on the symbol of datum/compass align it with the tooling axis.
• Click on the surface and see that the surface is within the permissible limit of the draft values.
• Be ensuring that the surface should be green and if not flip the direction of the datum/compass it will turn into green.
• And after flipping the direction still not the draft analysis is not working, close the command and delete the 'Free From Analysis' and perform the process, it will start working.
• And if found that some area is still not turning into green, check the geometrical set or set the tooling axis with different values.

NOTES: - FINALLY I ACHIEVED THE SURFACES BUT STILL THERE WERE SO MANY PROBLEMS TO ACHIEVE THOSE SURFACES. SO MANY TIMES IT IS NOT JOINING, IT IS NOT TRIMMING, AND IT IS SHOWING TROPOLOGICAL ERROR, CONNEXITY ERROR AND TANGENTIAL ERROR. I HAVE CHANGE THE PROCESSES STILL DIDN’T ACHIEVE IT, SO I HAVE TO USED SOME DIFFERENT METHOD OR PROCESSES TO ACHIEVE THE FINAL CLOSED SURFACE.