Week 8 - Challenge 2 - Switch Bezel Design
Aim -
Create the Switch Bezel Plastic component through the given Class - A surface
Objective -
The objective of the project is to design the switch bezel and to do a draft analysis for it by creating the required tooling direction with the help of Bisecting method
Introduction -
The control panel bezel is the frame part of the window switch that holds its switch covers and buttons into a place. moulding is the method used to manufacture the plastic trims of an automotive by most OEM's hence by considering the manufacturing consideration the switch bezel is designed.
Design Consideration
1. Class - A surface should be aesthetically smooth and good.
2. Class - B surface should have all the supporting features like ribs.
3. Parting line should coincide with the B surface since flashing couldn't affect the aesthetic of Class - A.
4. Class - C surface should also pass the draft analysis.
Procedure For Creating the Switch Bezel.
Creation of Tooling Direction -
1. considering the ejection from the cavity of the mold after manufacturing the switch bezel. (must have the nominal 3- degree draft angle)
2. Hence the tooling direction is created by considering the above factor and bisecting method is used.
3. 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.
4. Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle
5. The green colour area shows that it satisfies the 3 degree draft angle. If not satisfied then by using the Runnind point the area is measured and then altered to get a succesful draft for the created tooling direction.
6. Min. 0.3 degree of deviation is allowable so we take 2.9 value for draft analysis.
Class A Surface -
Creation of Class - B surface
1. For creating the class - B surfcae the required surface except the offset surface have been extracted and then untrimmed all the surface.
2. Then all the surfaces have been extrapolated to get intersections between them.
3. Since the thickness of the Switch bezel is 2.5 mm the B- Surface was offset to 2.5mm and the required trim operations must be carried out.
4. Finally, the required corners have been filleted 14mm ( 14-2.5=11.5mm).
Class C Surface -
Creation Of Class - C surface
1. The requred outer edges of the A- surface were extracted using Multiple Extraxt. Then for avoiding the patches the curve is smoothened using the curve smooth option.
2. Then by using the sweep command the surface was created with following feature controls.
Profile type - line
Subtype - With Draft direction
Guide curve - smooth curve
Draft Direction - Tooling axis
Draft computation Mode - Square
Angle - 3 degree
Angle Sector - Positive Downwaed
Length - 20mm
3. Then by using extrapolate command the edges were intersected between the surface corners which eases the trimming operation
4. Now the requred portion of the c - surface were trimmed out.
Then By joining Class A and Class C surfsce Trimed out the B surface and get the surface model
Now By using Close Surface Command we created a close Body surface -
Procedure For Draft Analysis -
1. First the class - A surface is checked before creating the Class - B & C surface and finally the solid body must be analysed . Both cab be done by following the below procedures.
2. By changing the view mode to custom view parameters - Material mode then the feature draft analysis is enabled.
3. Then the compass was activated and placed with the tooling axis by dragging the redpointer and then lockes it
4. Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle
5. The green colour area shows that it satisfies the 3 degree draft angle. If not satisfied then by using the Runnind point the area is measured and then altered to get a succesful draft for the created tooling direction.
Here Draft angle More than 2.9 degree region shows in green colour, Then draft angle between 0 to 2.9 degree shows in sky blue colour and draft angle below 0 degree shows in red.
Conclusion -
As we check in that blue area draft angle show 2.2 but all other is in green zone. Hence we need to inform styling engineer to change the class A surface.