Week 9 - Challenge 3 - Bumper

BUMPER DESIGN

Create the Bumper Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Take the Thickness of the component to be 3 mm

AIM :

To create a body of Bumper from the input given which was the A-surface of a Bumper. The created body should be a closed solid volume which should be feasible for manufacturing and Tooling. The draft angle and draft analysis of the component should be done.

In model, proper tree structure to be maintained and publications of Tooling axis,A,B and C surfaces to be done.

CLASS A SURFACE(given)

TOOLING AXIS

Tooling axis represents the opening and closing of the mold core and cavity during the manufacturing of the components. A plastic product designer should consider the best tooling direction to cutdown the cost of the component very less.

Method opted for creating tooling axis for the bumper

• Check the best tooling direction for the given surface.
• We can find out the best tooling direction by cross checking all the three axes.
• Here we can find out that the best tooling direction for the pumper class-A surface is along x-axis direction
• The method I choose to create the tooling axis is first extracted a surface and create a midpoint on that surface. The introduced an axis system on that point.
• Then created a with the point and direction along x axis.
• Here both the outer flanges have 5.1-degree draft with respect to the axis created. Hence going with the axis created will not make any difficulties during the draft analysis.

DRAFT ANALYSIS (CLASS A)

The Draft Analysis is a command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

CLASS B SURFACE

Class-B surface means thickness of a part it is not visible and is inside part. In other words, Class-B surface is a surface below a certain thickness from the class-A surface. This is the surface that contains engineering aspects of a model.

• Offset the class-A surface to 3mm inward direction.
• Rework on the patches and discontinuity of the offset surfaces using the features like extract, multi-extract, sweep, multi-section surfaces, extrapolate.
• To ensure the continuity of the Class-B surfaces check the boundary command to find out the boundary.

• Hence class-B surface creation is done.

CLASS C SURFACE

Surface that joins class-A and class-B surfaces is class-C surface. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled

Since it is a complex class-A surface, we cannot simply create the class-A boundary curve and sweep it at one shot. Hence, we need to create smaller curves using multi-extract command and then create sweep of 90 degree with reference to the surface option. sweeps at the midportion of the bumper should have a 93 degree vaue to pass the draft analysis.

CLASS A & C SURFACE

• First step is to join the CLASS-A surface with CLASS-C surface.

FINAL SURFACE

• Then Trim the Joined surface with CLASS-B surface to achieve the final Bumper surface.

SOLID BODY

All the surfaces (A,B,C) are joined together to form a closed body.

Boundary is selected and the body is picked. Since an error popped up it can be understood that all surfaces are joined with each other to form a proper closed surface body.

Finally in part design workbench, using close volume it is changed to a solid body.

DRAFT ANALYSIS OF PART BODY:

• The final solid part body has to be analyzed using Draft analysis. This is done to check if all the areas of the body are satisfying the draft angle which is 3 degrees.
• A draft angle is a taper applied to the vertical walls of the injection-molded component to assist with releasing the part from the mold.
• Draft angles are a required feature of injection-molded custom parts. A functional part for injection molding has to have draft angles that face both the cavity and core sides. This will reduce the risk of damage to the parts and ensure that they can be ejected from the machine.
• The Bumper body is checked using Analysis and images for it are shown below.

Conclusion:

The Draft analysis of the component showed that the component is feasible to be molded without any issues.

Thus it satisfies all design and manufacturing criterias needed for a proper part.

This concludes the report of Design of Bumper Body.