Week 9 - Challenge 3 - Bumper
BUMPER DESIGN
AIM:
TO CREATE A FRONT BUMPER WITH GIVEN STYLING DATA.
FRONT BUMPER:
ONE OF THE LARGEST AND COMPLEX EXTERIOR TRIM PART WHICH CARRIES MANY SYSTEM ON IT.
MORE FREQUENTLY CHANGING PART IN FACELIFTS.
FRONT BUMPER PLAY A VITAL ROLE IN THE FRONT LOOK OF A VEHICLE (AESTHETICALLY).
INJECTION MOLDING PROCESS IS USED TO MANUFACTURE THIS PART.
IT IS MADE OF A MIX OF VARIOUS MATERIALS LIKE ALUMINIUM STEEL AND THERMOPLASTICS ETC.,
POLYCARBONATE ALLOYS ARE USED NOWADAYS BECAUSE OF THEIR LIGHTWEIGHT AND EASILY MOLDABLE PROPERTIES.
STEPS FOLLOWED:
- VISUALLY CHECK THE GIVEN CLASS A FOR GAPS.
- TOOK A LOOK AROUND PART FOR THE TOOLING AXIS.
- CLASS A DRAFT ANALYSIS.
- CREATION OF B SURFACE FOR GIVEN THICKNESS VALUE.
- CLASS C SURFACE CREATION.
- CLASS A AND C SURFACE JOIN.
- TRIMMING A+C SURFACE WITH THE B SURFACE.
- CLOSED SURFACE FEATURE FOR SOLID CREATION.
- DRAFT ANALYSIS FOR SOLID PART.
- PUBLICATION OF CLASS A,B,C AND TOOLING AXIS.
CLASS A SURFACE:
TOOLING AXIS CREATION:
VISUALLY VIEWED THE PART IN ALL THREE DIRECTIONS.
IN THE "X" DIRECTION ONLY MOST OF THE FACES IN THE PART ARE VISIBLE.
SO CREATED A DUMMY TOOLING AXIS IN THE ASSUMED DIRECTION.
CHECKING DRAFT ANALYSIS FOR CLASS A WITH DUMMY TOOLING DIRECTION.
Z-DIRECTION
Y-DIRECTION
X-DIRECTION
IN X ONLY MORE SURFACES ARE CLEARLY VISIBLE SO CREATED TOOLING AXIS IN X- DIRECTION.
CREATED ON THE FLAT FACE (LICENSE PLATE SURFACE).
CLASS A DRAFT ANALYSIS:
3 DEGREE DRAFT CLEARING
CLASS B SURFACE CREATION:
STARTED TO WORK ON CLASS B AFTER THE TOOLING AXIS WAS FIXED.
CLASS A HAS OFFSETED FOR THE GIVEN THICKNESS VALUE.
SURFACES AND SOME FILLET AREA PARTS ARE NOT OFFSETED FULLY.
THE GAPS NEED TO PATCHING.
PATCHING PROCESS:
REMOVED THE NON-CONTINOUS FILLET SURFACES.
EXTENDED AND TRIMMED THE ADJECENT SURFACES WITH EACHOTHER TO CREATE A SHARP EDGE.
LATER MEASURED THE FILLET VALUE FORM STYLING AND GIVEN RADIUS ACCORDINGLY.
SECTIONING OF CLASS A AND B DONE TO CHECK WITH CURVES.
TO ENSURE PROPER OFFSET PARTICULARLY IN FILLET AREAS.
CLASS C SURFACE CREATION:
C SURFACE IS CREATED USINF BOUNDARY, EXTRAPOLATE, SWEEP AND TRIM COMMANDS.
EXTRACTING CLASS A BOUNDARIES.
FACES WHICH ARE PERPENDICULAR TO THE TOOLING AXIS IS SWEPT WITH DRAFT ALONG TOOLING DIRECTION.
FACES WHICH ARE PRALLEL TO THE TOOLING AXIS IS SWEPT NORMAL TO RESPECTIVE WITHOUT DRAFT.
EXTENDING THE SURFACES UNTILL IT INTERSECT AND TRIMMED.
FOG LIGHT SECTION DONE SEPERATLY DUE TO HAVING A LOOP SEPERATE.
'A' AND 'C' JOINED:
AFTER A AND C JOIN EXTRAPOLATED UNTILL IT MEET THE CLASS B SURFACE.
'A' 'B' AND 'C' JOINED:
AFTER THE FINAL JOIN I USED SYMMENTRY OPTION TO MIRROR THE PART.
AT LAST BOTH ARE JOINED.
CLOSED SURFACE:
USING CLOSED SURFACE COMMAND CREATED SOLID PART IN PART DESIGN WORKBENCH.
FEATURE TREE COLLAPSED:
DRAFT ANALYSIS:
ANALYSING FOR 3 DEGREES
VIOLET DOTTED LINE - TOOLING AXIS.
FEATURE TREE EXPANDED:
CONCLUSION:
IN THIS CHALLANGE I HAVE MADE A BUMPER CAD MODEL WITH THE GIVEN INPUTS AND CLASS A SURFACE AND ALSO CLEARED DRAFT ANALYSIS FOR 3 DEGREES.