Week 9 - Challenge 3 - Bumper

Week 9 - Challenge 3

Bumper Design

Object

Create a tooling axis in proper way for finding better draft analysis from given class A surface. Create draft analysis of class A surface and create class B and class C surface from class A surface. And finally create draft analysis of finished body.

Consider the thickness of the component 3 mm.

Bumper

A car bumper is a crucial component that serves multiple purposes, primarily protecting the vehicle's front and rear ends from minor collisions and minimizing repair costs. Over the years, bumpers have evolved significantly, transitioning from rigid metal structures to lightweight, energy-absorbing designs that prioritize safety and pedestrian protection.

Materials and Construction:

Modern bumpers are typically constructed from a combination of lightweight materials, including:

• Plastic outer fascia: This provides a durable, aesthetically pleasing exterior layer.
• Shock-absorbing foam core: This layer absorbs impact energy, crumpling in a controlled manner to reduce damage to the vehicle and its occupants.
• Reinforcement beams: These internal structures provide additional support and protection in case of more severe collisions.

Design and Functionality:

Bumpers are designed to fulfill several key functions:

• Protect the vehicle: Bumpers act as a barrier, absorbing impact energy and minimizing damage to the vehicle's bodywork and components during low-speed collisions.
• Improve safety: Modern bumpers are designed to mitigate injuries to pedestrians in case of a collision. They incorporate energy-absorbing materials and rounded shapes to reduce the severity of impact.
• Enhance aerodynamics: Bumpers can be shaped to streamline airflow around the vehicle, improving fuel efficiency and reducing drag.
• Accentuate styling: Bumpers play a significant role in the overall appearance of a vehicle, contributing to its aesthetic appeal and design language.

Types of Bumpers:

There are two main types of car bumpers:

• Front bumpers: Located at the front of the vehicle, front bumpers are designed to protect the vehicle's grille, headlights, and hood from collisions. They often incorporate air intakes for engine cooling and fog lights for enhanced visibility.
• Rear bumpers: Located at the rear of the vehicle, rear bumpers protect the taillights, trunk lid, and exhaust system. They may also incorporate parking sensors and reverse lights.

Introduction

This project is done on CATIA software. This software is different from other. It is easy to designing for surface modelling. Its have more accuracy than other.

Class A Surface

In automotive design application Class A Surfaces are created on all visible exterior surfaces (ex; body panels, bumper, grill, lights etc.) and all visible surfaces of see-touch & feel parts in interior (ex: Dashboard, seats, door pads etc.). This can also include beauty covers in the engine compartment, mud flaps, trunk panels and carpeting. This surface has 0 mm thickness.

Given Class A Surface

Tooling Axis

Tooling axis or tooling direction is main consideration for plastic part and mold parts because it defines movement of mold part and possibility of plastic part to come-out from mold part (Core and Cavity). In Molding machine arrangement is given to open the mold along a direction which is known as Tooling Direction. The mold is built from two separate halves (Core and Cavity) and tooling direction basically define the direction of mold pulls apart. Tooling direction is known as primary direction.

• Here I have created a tooling axis. First of all I extract a base surface and create a mid pont on it. And then I create a line through this point with perpendicular to base surface. And then I performed draft analysis ans I saw every thing is ok. Then finally it is my tooling axis.

Draft Analysis

The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line. Draft Analysis is applicable for 3D part models. To create a draft analysis for any 3D part file, the user needs to select part/surface select the pull direction. You can change the pull direction.

Draft Analysis of Class A Surface In CATIA

It provides colour based identification. With the help of this we can easily find that which surface is in clear and which is in stuck by colour changing. Here I give the draft angle 3 degree. The result in colour based that the surface which green (means draft angle > 3 degree) is right. And where the colour is blue mean draft angle is 3 degree to 0 degree if this surface area is low then you can go. If you find red colour zone then it means draft angle is less than 0 degree. Then you will have to create tooling axis by another way if possible, otherwise you can say your design engineer to correct for designing.

Class B Surface

The surface which is back side of Class A surface is called Class B Surface. Mostly it not visible. It is created with the help of Class A surface with some distance (thickness) like 2mm, 3mm etc.

• Here I created Class B Surface on 3mm from Class A Surface.

Class C Surface

The Class C surface is the back side of a part of a surface that is permanently covered by another part.

• With the help of join and trim feature I have created a closed surface body.

Draft Analysis of Part Body

I have allready descrived above on it. You can see there.

Feature Tree and Some Views of this Part

Different views

Conclusion

In this project we learnt that how to find tooling axis in appropriate way and how to create Class B and Class C Surface from Class A Surface.car bumpers have evolved from simple protective structures to sophisticated components that play a vital role in vehicle safety, style, and functionality. Their design and construction have advanced considerably, incorporating energy-absorbing materials, safety features, and aerodynamic considerations.