Week 8 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL

To create B and C surface from the given class A surface then create a closed solid body and analysis the draft angle for the same.

Steps followed for the process

• After receiving the class A surface check the connectivity of the surface and ensure it is completely joined and there will be no gap between the surfaces.
• If it is not joined together make it with a minimum tolerance of 0.001 to 0.003 and check for connectivity of the surface.
• Connectivity of the surface can be done in two ways by the join method and by boundary method.
• Split the surfaces into multiple profiles then Identify the surface where it is not possible to create a tooling axis and check which direction is best fit for tooling axis and then define the tooling axis and draft direction.
• Here for defining the tooling axis first we have created a point at the middle of the base surface and create an axis with respect to that point then define the dummy tooling axis using the intersect method by creating a bisecting line.

Tooling axis creation

• The direction in which the mould open and closes is called the tooling axis direction.
• Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
• While creating a tooling axis please ensure to give the tooling axis on a flat length surface or the surface which have a hole in it.
• Create a point on the middle of the base surface by using a point on the surface command then create a boundary for the surface and extract the reference lines which will be helpful for creating the tooling axis.
• Use the line command and draw the lines which are aligned with the extracted lines then create an axis.
• Bisecting method
• Identify on which plane we have to do more operations and create the plane or axis on the component area and define it on the dummy tooling axis direction.
• Intersect the class A surface with that plane then we will get an intersection sketch. Look for the profile (inclined line) which will create a problem and extract it then extend it by using the line command.
• Then create a bisecting line with reference to the lines we have extended and this will be our main tooling axis.
• , In this case, we have created two dummy axis along with the Y direction and Z direction then we have created a line by using bisecting option and this will be our main tooling axis.

Then do a draft analysis on the class A surface and identify the draft angle then give the nominal value for the draft.

Draft analysis

• Draft allows for the component to release from the mould, most parts or applications require a minimum of 0.5 to 1 degree draft angle and 3 degree draft angle is widely used as per the norm.
• Change the material mode to customize mode before moving to the draft analysis.
• Insert –analysis-feature draft analysis
• Defining the draft direction Select draft analysis from the toolbar and click on the compass symbol and pull the compass from the right-side top corner of the workbench and place it on the component where want to do the draft analysis. ‘W’ of the compass and tooling axis should be aligned on the same line.
• Once the compass is aligned with the tooling axis click on the lock symbol and drag on the surface we will get a wrong mark then select that point a table will appear it shows the draft value on the table we can adjust the draft value and analysis it for all the edges and surfaces.
• By clicking the on the surface and using the flipping tool we can assign the Flipping direction, the color of the surface change as per the flipping direction.
• Analysis under running point and move the mouse on the surface and it will show the details of the surface deg direct at each and every point of the surface.

Class B surface

• In the case of Class A the surface below is called the core and the surface above is called the cavity.
• Class A is an aesthetics surface and class B is an engineering surface.
• B surface should be inside the class A surface.
• B surface can be divided into three surfaces the bezel rest surface ,walls and the base surface and later trim them altogether.
• First step is to create the bezel rest surface by extracting the required surface from Class A and untrimmed it thus we will get a single surface which will be extrapolated to get the required size and finally offset it to the inner side of Class A as per the thickness of the material.
• The walls can be extracted by selecting the wall surfaces from class A except the edge surfaces then untrimmed, extrapolated and trimmed it to get the required shape and offset it for the required size of the material.
• Base surface of the component is then extracted, untrimmed, extrapolated and offset.
• First bezel rest surface and the walls are trimmed then it is trimmed with the base surface now all three geometries are trimmed together to get the B surface.
• Fillet is applied to the required surfaces by measuring the fillet value from the class A surface thus we will get the final B surface.

Class C surface

• C surface has been created with reference to the boundary lines of the class A surface and sweep it with reference to the tooling axis then the holes are created by following the same method.
• In order to get the C surface first we have to create a boundary line of class A surface or by using multiple extrapolated command and check for its continuity of it. If it is not in a proper line then split it into multiple boundaries and smooth curve it with a maximum deviation of 0.001mm by the curvature continuity method.
• Create a sweep with reference to the smooth curve and the tooling axis with a nominal three degree draft angle and make it for all the split curvature. Check for the continuity of the surfaces if there is any gap go for extrapolated and trim all together now we will get the class C surface.

Then join the class A surface and C surfaces together by the join command then check for connectivity of the surfaces if it is ok, then finally trimmed it with B surface we will get the final component again and check whether the final body is closed by using boundary command.

• Close solid body can be obtained by using the close surface on the part workbench by selecting the final Trimmed component.

In this case, we are not getting a completely closed body so to solve this error we are doing the following steps.

• Increase the merging distance up to 0.003mm on the join and then check the connectivity of the surfaces. if it fails again we have to modify the class A and C surface.
• Extrapolate the bezel rest surface edges of class A and class with a minimal value.
• Then trim the modified class A with class C surface and check the connectivity of the surfaces thus creating a closed body.
• Closed solid body is created by using the close surface on the part workbench by selecting the final Trimmed component and doing the draft analysis for the same.

DRAFT ANALYSIS ON THE CLASS A SURFACE

DRAFT ANALYSIS ON THE FINAL SURFACE

CLOSED SOLID BODY

DRAFT ANALYSIS ON THE CLOSED SOLID BODY

zip file is attached