Challenge

Week 8 - Challenge 2 - Switch Bezel Design

SSaravana Kumar17 Mar 2023

AIM:

The aim of this project is to develop the product design of the switch bezel with the help of the class A surface following the OEM standards.

OBJECTIVES:

To design switch bezel as per automotive OEM Standard.

Create B Class and C Class and tooling axis.

Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.

Performing draft analysis to verify the creation of the Tooling axis and C Class surface.

DESIGN ABSTRACT:

I design a Switch Bezel using Catia v5. I received input as Class A Surface. I Check the direction to eject the tool based on the component design. Later I checked whether all faces that intersected will clear the direction based on the tooling axis. I started working on the Draft Analysis tool to check if our tooling direction clears the path for easy removal of material from the tool. After that, I go class B creation using Advance tools from the surface followed by class C creation using the sweep command. after design A B C class surface, converting close surface into solid inside the part workbench.

PROCEDURE:

TOOLING AXIS:

A Reference Point is created along the Surface zero and new Axis system is created

The X Direction along the Class A and Y direction along the Class A were used to create Tooling direction

Finally the Tooling axis is created by bisecting the two lines and it is published. Class A Surface as input using surface operation commands Class B is developed

The tooling Axis determines the direction of Class C boundary swept with draft direction.

When viewing from tooling direction normal all the parts that are drafted should be visible so it gives an rough idea to determine product manufacturing in Injection molding.

CLASS B SURFACE:

The next step is to design B surface for the input which is usually the surface where all engineering aspects and support creations are done.

The B surface Creation is performed using surface operations in CATIA which is an offset from Class A with dimension proportional to the thickness of the part

In Switch bezel the B surface is offset 2.5mm from the input which is the thickness of the part

The B surface is an extrapolated surface compared to A surface and forms the bottom skin of the part.

base surface and side wall and bottom surface are trimed respectively.

finally edge fillets are to be proceed in the corners.

CLASS C SURFACE:

The Next step is to from the C surface which is an intermediate surface between A and B and is used to give the closed surface appearance to the design.

The C Surface is swept using the profile as boundary line of Class A which is the Guide curve with a subtype along draft direction.

The Direction of the sweep is the tooling direction formed earlier.The draft angle for the sweep operation is provided which is 3 Degree and surface is swept for length above the thickness of the specified part.

The Closed surface is then validated to find the irregularities along the edges and imperfections along the edges were then corrected using operation like extrapolate and surface trim

both the corners are to be extrapolated in some distance then trimmed together.

Finally the Class A and Class C surfaces are joined together and connexity of surfaces should be less than 0.003mm and the surfaces are merged.

then the output of the class a and c joining surface will be trimmed by using the class b surface.

SOLID PART BODY:

Solid body is created by a closed surface feature in the Part Design workbench in the defined partbody.

DRAFT ANALYSIS:

The part created has to be changed to material mode in display frameThen by enabling compass definition the axis system is pan along the direction of the part and aligned in line with the tooling direction.

Lock Direction is applied that fixes the compass and then the mode dialog box is formed by snapping at any point on the part The Color Codes are classified and Draft Angle are appliedThen the Running point analysis is used to over around the part to analyze the permissible draft angles and the analysis is saved.