Week 8 - Challenge 2 - Switch Bezel Design

AIM:

• To make the model from the provided input class-A surface.

INTRODUCTION:

• To create the model using the reference of Class-A surface.
• The class -B surfaces are created by the extraction of class-A surfaces.
• The class-C surfaces are created by extracting the outer boundary of the class-A surface and applying the swept feature.

METHODOLOGY:

• In this model we have to consider the following things:

1. Tooling axis
2. Draft analysis
3. Class-A surface
4. Class- B surface
5. Class-C surface
6. Making a solid model from the surface.

TOOLING AXIS:

• Tooling axis is the defined axis to perform the manufacturing process within the injection molding according to its direction.

CREATION OF TOOLING AXIS:

To create the tooling axis for the switch bezel design.

It has three adjacent tapered faces with the bottom closing base surface.

So we can't create the tooling axis for entire tapered faces.

First, we analyze the model in which direction is suitable for the appropriate particular tapered faces.

Create the tooling axis perpendicular to the bottom face and parallel to both sides of tapered faces and create the tooling axis perpendicular to the same bottom face and parallel to the remaining side tapered face then bisecting the two reference tooling axis to get the main tooling axis.

REFERENCE TOOLING AXIS 1:

• Extract the bottom face from the class A surface.
• Make a point at the center of the bottom face and position the axis system on the point.
• Create a positioned sketch with reference to the yz plane.
• Cut the part by sketch plane.
• Intersect the plane with class A surface by using the intersecting 3D element command.
• Sketch the line on the intersecting profile which is lying parallel to the considerable tooling axis.
• Create the bisecting line to reference of sketched line on the intersection profile and called it as reference tooling axis 1.

REFERENCE TOOLING AXIS 2:

• Create a positioned sketch with reference to the zx plane.
• Cut the part by sketch plane.
• Intersect the plane with class A surface by using the intersecting 3D element command.
• Here one side of intersecting profile takes place. so sketch the line on intersecting profile which is lying parallel to the considerable tooling axis.
• Sketch an inclined line from point to sketched line on the intersecting profile and give the angle of 5 degrees between the two lines to maintain the nominal draft while performing the draft analysis.
• 

MAIN TOOLING AXIS:

• Finally create the bisecting line by reference to tooling axis 1 and 2.
• Bisected line is called as main tooling axis.

DRAFT ANALYSIS:

• The analyzing of the model should maintain the nominal 3-degree draft angle to the tooling axis.
• Draft should be given to the plastic component to reduce the wear and tear and improve the production quality and accuracy while ejecting the part from the mold cavity.

How to perform the draft analysis

1. Go to insert < analysis< feature draft analysis.

2. Align the tooling axis with a compass.

3. Click on the surface to see whether it is in permissible limit draft values or not.

4. The entire surface should be green in colour.

DRAFT ANALYSIS FOR CLASS-A SURFACE:

DRAFT ANALYSIS FOR MODEL:

CLASS- A SURFACE:

• Class-A surface is given as an input surface by designers.
• Generally the class-A surfaces have the tangent continuity
• Class-A surface is the outermost aesthetic surface.

CLASS-B SURFACE:

• The extraction of the Class-A surface is the class-B surface.
• Untrimmed the extracted surfaces from class A.
• The untrimmed surfaces are offset to the required thickness.
• After offsetting, all the surfaces are trimmed into the required shape.
• Give the fillets on the edges, especially given fillet radius values should maintain the uniform wall thickness.
• The class B fillet radius value=outer radius value + thickness.

CLASS C SURFACE:

• Class C surface is the closing surface of class A and class B surfaces.
• It is the extraction of the boundary of class A surface.
• Apply the sweep feature to create the class c surface, For guide reference click the extracted boundary and for the drafting reference option click the tooling axis and give a 3-degree draft angle.

FINAL COMPONENT IMAGES:

SOLID BODY IMAGES:

EXPANDED TREE: