Week 9 - Challenge 3 - Bumper

TO 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

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

INPUT GIVEN:

• A-Surface

• Thickness of component is 3.00mm

• Draft angle is 3 degrees.

CHECKING THE INPUT - A SURFACE:

The A-surface or the styling surface is first checked for any gaps and other issues in its surfaces. This Surface acts as the input surface so any correction to be done should be with approval from the styling team or done by them. A- perfect surface is the one when a boundary is created, the lines are only on the edges of a component and its holes or cutouts as shown below.

Procedure for creating the 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.

DRAFT ANALYSIS OF CLASS A SURFACE :

Draft analysis of the surface is carried to check if the surface or part can be manufactured with the required draft angle.

Draft angle is needed for the component to clear the core and cavity surface as it would have shrunk towards the center while cooling.

The draft angle in this design is 3 degrees. As A surface is a single surface there won't be much difference in color. The draft analysis of A-surface is shown below

SURFACE-B CREATION

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.

SURFACE-C Creation

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 3 degree vaue to pass the draft analysis.

Creating the final surface of Bumper

• First step is to join the CLASS-A surface with CLASS-C surface.
• Then Trim the Joined surface with CLASS-B surface to achieve the final Bumper surface.

FINAL DRAFT ANALYSIS

Conclusion : The Bumper is created with consedering all Design Methodology.