Challenge

Week 8 - Challenge 2 - Switch Bezel Design

Switch Bezel Design

Aim:

To Create the Switch Bezel 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

Class A surface:

After receiving the clasa A surface check the connectivity of the surface using join or by boundary.
If it is not join together make it with a minimum tolerance of 0.001 to 0.003 and check for connectivity of the surface.

Tooling Axis:

The direction in which the mould open and closes is called the tooling axis direction.
Here, using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
Then bisecting lines with the two inclined lines were drawn.
Now the same procedure is done along the xz plane but on one side we don’t have inclined lines so the centre point is used to extrude a line along the z-direction and gave a measurement of 6.5 degrees
With these two lines from sketches 1 and 2, the bisecting line is crated and published as Tooling Axis.

Class B surface:

B surface can be divided into three surfaces the bezel rest surface ,walls and the base surface and later trim them altogether.
First step is to extract the surface and untrim the surface and extrapolate to required limit and offest the surface to 2.5mm(required thickness).
Then same step follows for the Walls and base surface.
Then trim the surfaces same as 'A' surface.
Then Fillet the surafce by measuring the suraface of A surafce.

Class C surface:

Take the outer boundary of the A surface and use sweep command , take profile as boundary and Tooling axis as draft angle

Final Surface:

Join the class A and Class C surface and trim the joined surface with Class B surface.

Draft Analysis:

Draft Analysis of Class A surface

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.
The colour scale on the bottom visualizes, whether the draft angle meets the requirements or not (3 deg) by indicating the colours Green, Blue and Red. We need to align and fix the compass to the tooling axis then the draft angle analysis will be checked out.

Draft Analysis of Solids in various orientations

Front View: