Challenge

Week 8 - Challenge 2 - Switch Bezel Design

SSandeep M7 Mar 2023

AIM

To Create the Switch Bezel Plastic component through the given Class-A surface.

THEORY

Tooling Axis

Tooling Axis is the direction in which the mold or core and cavity opens and closes. While designing a component first thing is to define the tooling axis.

Procedure

Check the connectivity of given Class A Surface i.e no gaps between the surfaces.
Analyse the component along x,y,z direction and check which is the best possible tooling direction (Here Z)
Create a point at base surface by extracting it.
Create an axis system with that point as origin.
Create intersection through zy axis using "Intersect 3D Elements. Create two lines with reference of faces which we think will create problems.
Create a bisecting line with the lines drawn. This is the tooling direction along zy direction.
Repeat these steps for zx axis. Here there is only one face and other is open. so create a line at particular angle (can be any value greater than or equal to minimum draft angle) with reference to the face which we think will create problems. These angle can be adjusted if it fails to meet the draft analysis.
Create a bisecting line with these two sketches along the origin point, which will gives us the tooling axis.

Draft Analysis

Draft analysis is used to analyze whether the part model created in CAD id manufacturable based on the draft condition applied.

Draft is required on all parts in the direction of mold movement in order to allow parts to release or eject from the mold properly. Most part or application require minimum `0.5^o - 1^o`as draft angle, however `3^o` is widely accepted as the norm.

Procedure

First change the view to " Customize View Parameters" and select Material option.
Select Feature Draft Analysis from the tool bar.
Click on the direction, drag and drop the compass to the component such that it should coincide with the tooling axis.
Lock the draft direction and click on the component.
Green colour shows the positive draft, cyan as zero degree and red as negative draft

Class A Surface: Class A surface is any of a set of freeform surfaces of high efficiency and quality. In other words, Class A surface is the aesthetic surface.

Class B Surface: Class B surface is the thickened suface or engineering surface where all ribs etc will come.

Class C Surface: It is the Surface which joins Class A and Class B surfaces.

SOFTWARE USED

Catia V5

DESIGN

Thickness Given: 2.5mm

Tree Structure