Week 8 - Challenge 2 - Switch Bezel Design

Submitted by: Syed Rizwan Ali
Course: Automotive Plastic design using CATIA V5
Challenge: Week 8 - Challenge 2 - Switch Bezel Design

1- A detailed report should be done explaining the draft analysis and the tooling axis creation.

Draft analysis on Class A surface of Switch Bezel below-
Step 1- Open draft analysis and move the compass to coincide with Tooling axis as below

Step 2- Lock the compass and check the radius using the running analysis option-

Step 3- Set the color code for the draft angle i.e green for above 3 degrees, Blue for 0-3 degrees, and red for angle value lesser than 0.

Step 4- Click on the surface using light effect, if the color goes green throughout means your draft analysis is good and ready for manufacture-

Now Creating Class B and Class C surface for switch Bezel-

2-An explanation should be given on the way of creating the tooling axis, particularly the Bisecting method.

ANS- Tooling Axis-

Now creating the tooling axis by using bisecting line and a dummy axis-
1. open the file which contains the Class A surface, after creating a geometrical set "Tooling Axis" then select the most appropriate position, and in this select a base of the tab/pocket.

2. Then create a point at the surface extracted then draw a dummy line on the z-axis.

3. After that create a plane on the point created with reference to XY plane direction.

4. Then select the intersect tool that gives the intersection on the Class A surface.

5. Now create 2 lines using the point and direction method as shown below screenshot.

6. the Last step creates a bisecting line using the above 2 lines.

Have a look at the Screenshots

The above line is made for the Y direction and making the line for the X direction with the same procedure used above
But in this, we need to draw a line manually and keep its angle to 6 degrees-


The final step for the Tooling axis -
Bisect the lines created in sketch 9 and sketch 11 using the bisecting line command-
Color it yellow and published it.

Creating Class B surface-
1- BEZEL REST SURFACE-

2- Walls

3-Base

Final Output of B surface-

Creating Class C Surface- Using Sweep command and Class A Surface-
Smoothing the curves

The final Surface output which will be getting solid using the close surface command in part workbench-

Draft Analysis on the solid part-

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Thank you