Week 9 - Challenge 3 - Bumper

Class A Surface:

Check the connectivity of Class A Surface.

Using the connect command, make sure there are no gaps between the components. We may physically inspect it or use the border command to do so. One outside and two inner circular limits make up its three borders.

Find a suitable tooling axis and create one.

Look carefully to determine the ideal tooling axis. Verify each axis.

Bisecting method: This technique is used to generate tooling axes for that purpose. First, the direction of molding must be decided. Next, a fake tooling axis is created for the purpose of reference.

TOOLING AXIS:

To create the tooling axis, I extracted a surface from class A and created a point in the middle of the surface by using the point command and created a line at that point through the x-axis. Now, I performed a draft analysis check from that line whether the created tooling axis is in the correct position or not. If, in the draft analysis check the surface highlighted with green colour on both sides of the surface the tooling axis is in the correct position and direction.

CLASS B SURFACE:

To create the class B surface, offset the class A surface inside as per our thickness requirement (here the thickness is 3mm, so I offset the class A to 3mm inside). Once the offset is created, we can observe some patches on the offset surface by taking the boundary for the offset surface, those patches are formed due to the fillets on the class A surface. We need to cover those patches with the help of the multi-section surfaces command by extracting the patch boundaries. Once all the patches on the offset are covered properly join all the patches with the offset surface, to get the replicated surface of the class A surface.

CLASS C SURFACE:

To create the class C surface concerning the boundary of the class A surface, I used the sweep command. Initially, I extracted the boundary of the class A surface with tangent continuity, and I sweep the extracted boundary concerning the surface at 93deg (for draft angle) for 4mm to intersect properly with the class B surface. Once we sweep all the surface boundaries of class A, extrapolate the sweeped surfaces until both surfaces got intersected properly, and trim them to remove extended extrapolated surfaces to get a proper sweep boundary throughout the entire surface, including the centre hole of the bumper.
Now, join both class A and sweep boundary to get the complete class C surface.

Close Surface:

finally we got the close surface through the part design.