Challenge

Week 8 - Challenge 2 - Switch Bezel Design

SSidhartha Sankar Sahu4 Mar 2023

AIM : Creation of a Switch Bezel Plastic component of thickness 2.5mm through a given Class-A surface.

REPORT :

WHAT IS TOOLING AXIS : The direction in which the mold or core and cavity opens is the tooling axis.

HOW TO CREATE A TOOLING AXIS :

1) Before creating a tooling axis , as a preventive measure check the Connectivity of Class-A surface. it can be done by using the "join" or "boundary" command. using these command we can identify any unnecessary openings of the class-A surface.

no unnecessary openings are found.

2) visually analyse which is the best possible way to create the tooling axis , considering avoiding side cores, easy ejection of component from core, easy flow of molten plastic inside the cavity.

along 'y' tooling axis is not possible , along 'x' tooling axis is possible but considering two bigger flat surfaces are present in the 'z' direction , we will try to create tooling axis along 'z'.

3) In the pocket area we have 3 walls , we will make sure that every wall is clearing with the tooing axis , to confirm that we will perform Bisecting method.

we are planing to create tooling axis along 'z' so we will intersect the class-A with 'yz' & 'zx' plane.

4) Extracted the base surface because all the three walls are connected to this surface , and made a point in the center of the surface.

5) For 'yz' plane created a sketch and intersected the class-A , for the two walls in this plane , made two lines along the walls and then bisected them to find the partial tooling axis.

6) For 'zx' plane created a sketch and intersected the class-A , because here only one wall is present , considering the draft angle created one line along the wall and another in the middle of the surface with an angle of (3-6 degree) , and that is another partial tooling axis.

7) Finally bisected the two partial tooling axis to find the actual tooling axis.

Draft analysis :

After determining the tooling axis , Draft analysis is done.draft analysis is used to check whether the desired draft angle is maintained or not. Compass is used in the draft analysis command to define the draft direction. as an output of this operation , we will be receving a colored range table , which will clearly show which surface of the component is getting cleared or not with the required draft angle , and with that result we can modify the surface.

Draft analysis for class-A :

every surface is clearing with 3 degree draft angle .

Draft analysis for final plastic component :

every surface is clearing with 2.9 degree draft angle .

creation of final component from class-A surface :

Created a class-b surface from class-A surface by first extracting surfaces from class-a followed by untrim , follwed by extrapolate followed by trim , followed by offset and followed by final trim.

Then created class-c from class-A by first taking the boundaries from class a then sweep them along tooling axis with draft angle and then combined the sweeped walls with the class-A surface.