Challenge

Week 8 - Challenge 2 - Switch Bezel Design

Week 8 - Challenge 2 - Switch Bezel Design

Inputs:

Screenshots of the Draft analysis report for both the given Class-A surface and the final plastic component:

Class A Surface Draft Analysis Report:

Here below 3 various face angle verfied images as below by draft angle analysis method,

Final Product Closed Surface Draft Analysis Report:

Here below 4 various face angle verified images as below by draft angle analysis method,

Image of the complete Draft analysis:

Images of the color scale variant:

Screenshots of the solid model with the proper color code of the draft angle in various orientations and various views:

Detailed Report of the Switch Bezel Design:

I have start work with inputs of Class A surface which received.

Tooling Axis Creation:

To create a Tooling axis, firstly i did extract the class A base profile and create point on the surface.
Then made sketch for side walls center bisecting line for main tooling axis input 1.
Then second sketch is made of another axis line creation that with taking reference of the angular wall line create for 3 Dgree.
Then finally create Bisecting line with input of both sketch and that would be my tooling axis of the component.
I have publish the class A & Tooling Axis for easy access.

Below image of the tooling axis of concerned,

Class B and Class C Surface Create:

In order to creation of B surface, firstly i have extract side walls and untrim those all the extrapolate that after that offset those all surface as component thick value as 2,5mm.
Then Trim all together then made side wall of the surface and same method followed to create base and Bezel rest surface with offset of 2,5mm thick.
All together trim and finally i got B surface, then colored for easy identification.
Then i got extract the class A boundary in 2 batches then sweep it, here i got error so i used smooth curve to solve the error and made sweep now tha got C Surface.
Once after join the C & A then i had check the boundary finding to ensure my profile get closed or not, at that time i got open boundary in front side edge face then i extract the specified profile then trim together then i replace the latest curve with the join input and did update.
Now i got C surface.

Below picture is B Surface of Switch Bezel,

Below picture is Class A & C Join Surface of Switch Bezel,

Final Trim:

Once get the inputs of B & C surfaces then i join the Class A & C togther the trim it the results with Class B surface then i got the result of closed surface of the componenet.

Below picture is Final Closed Surface of Switch Bezel,

Solid Body:

Final solid created by inputs of the above final trimed Closed surface of Switch Bezel surface.

The above processed have followed to make the B & C surfaces for final product designing.

Note:

I herewith enclosed the final CAT Part in Zip format.
I request to use hide/show to check the hidden surfaces and draft analysis report into the CAT file.

Ship work like this
in your own course.