Week 8 - Challenge 2 - Switch Bezel Design

AIM:

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.

TOOLING AXIS:

• Considering the Ejection from the cavity of the mould after manufacturing the interior trim (switch bezel) must have the nominal 3-degree draft angle.
• Hence the tooling direction is created by considering the above factor and bisecting method is used.
• The base surface of the class – A was extracted and a point at the centre is created and an axis system was inserted to the point with the current feature is disabled.
• Then, 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 .
• With these two lines from sketches 1 and 2, the bisecting line is crated and published as Tooling Axis(tooling direction).

CLASS B SURFACE:

• For creating the class-B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.
• Then all the surfaces have been extrapolated to get intersections between them.
• Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.
• Finally, the required corners have been filleted to 12.5mm (15mm-2.5mm). [ 15mm - fillet value of the A-surface, 2.5mm – Thickness of the component ]

CLAS C SURFACE:

• The required outer edges of the A-Surface were extracted using Multiple Extract. Then for avoiding the patches the curve is smoothened using the Curve Smooth option.
• Then by using the sweep command the surface was created with the following feature controls,
• Then by using extrapolate command the edges were intersected between the surface corners which eases the trimming operation.
• Now the required portion of the C – surface were trimmed out.

CLOSED SURFACE:

• Now the class – A and Class- C surfaces were joined together by removing the gaps in-between them with the help of extrapolation(tangent continuity) and Trim surface.
• Then the exact surface of the Switch bezel was trimmed from the above-resulted trim surface with the class-B surface.
• Then, by defining the part body by using the Closed Surface command in Part Design, the component's solid body is created.

DRAFT ANALYSIS:

• A surface is checked before creating the Class –B&C surface and finally the solid body must be analysed. Both can be done by following the below procedures.
• By changing the view mode to custom view parameters – Material mode then the feature draft analysis is enabled.
• Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked it.
• Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle.
• The green colour area shows that it satisfies the 3-degree draft angle. If not satisfied then by using the Running point tool the area is measured and then altered to get a successful draft for the created tooling direction.

PLASTIC COMPONENT:

CLASS A SURFACE:

BISECTING LINE:

Bisecting line is the line splitting in two equals parts the angle between these two lines. Select a point as the starting point for the line. By default, it is the intersection of the bisecting line and the first selected line.

ISOMENTRIC VIEW:

FRONT VIEW:

SIDE VIEW:

TOP VIEW: