Week 9 - Challenge 3 - Bumper

Week 9 - Challenge 3 - Bumper

Aim: Creating the Bumper Plastic component through the given Class-A surface.  

Inputs:

• Class A surface
• Thickness of the component 3 mm

Process:

Step 1) Tooling Direction

Draft Analysis for Input to check proper Tooling direction

Checking the proper direction for Tooling axis. For this bumper part X direction is best suitable direction for tooling axis

A point is created on the edge of bumper & line is created in X-direction from point

Step 2) Creating Class B Surface

Offsetting the Class A surface to 3mm inside for part thickness given. After offset a few fillet patches & gaps generated in the surface.
Removed those patches and gaps by using following commands to create Class B surface

• Extract
• Multiple extract
• Boundary
• Extrapolate
• Split and Trim
• Join
• Untrim
• Fillet
• Sweep
• Close surface (in part work bench)

Step 3) Creating Class C surface

The A and B surfaces are connected by another single surface which is called the C surface. 

It is created by using a sweep with A surface acting as the reference surface and a curve created from the boundary of the same surface.

Sweep with draft direction is also used to create A-surfaces.

Step 4) Class A & Class C surfaces joined by using Join command

Step 5)

Used Trim command to create final closed surface of bumper body

Used Close surface command to create part body from surface body

Final views of part in different orientations

Isometric view

Front view 

Top view

Side view

Geometrical Tree Structure for proper understanding of process

Part Draft Analysis

Isometric view

Front view

Side view

Top view

Final part

Mirrored view

Result:

Bumper body plastic component created using CLASS A SURFACE with given thickness