Week 8 - Challenge 2 - Switch Bezel Design
Q) Creation of Switch Bezel Body with Draft angle
1) Design Check - This includes the checking the given Class A surface for any gaps at the boundaries. There should be no gaps between the surface boundaries.
(i) Given Class A Surface
To perform design check operation, select boundary command and click on the given Class A surface.
Open surface edges are highlighted in green color, therefore, Class A surface boundary will be highlighted in green color. It can be observed that there exists an additional green line on the Class A Surface. This indicates a presence of surface gap.
The surface gap as seen from the figure needs to be solved or closed as it would cause error in creation of solid body (close surface) from surface.
(ii) Surface gap closure
To close the surface gap, select disassemble command and select domain only option.
Noe select join command and click on the surface to check for the merging distance
The merging distance given was 0.001, let the merging distance be increased to 0.002 and check for surface gaps.
Now select the boundary command and click on the joined surface,
It is evident that the surface gap has been closed. Therefore, this new joined surface is considered as Class A Surface to proceed with further operations.
2) Creation of Tooling Direction
For tooling axis creation, all the axes directions i.e., x,y and z directions are to checked for easy removal of the mould and low tooling costs.
As observed the from the figure, the three directions or axes are shown among which one can be suitable for tooling axis or it could be in a direction that can be found using Bisecting method.
(i) Feasibililty Check in all directions
Y direction
X direction
Z direction
It can be seen from the above figures visibility or clearance of more number of faces is possible along Z direction compared to X and Y directions. Therefore, a tooling sxis or direction is created by considering Z direction as reference.
(ii) Creation of Tooling Axis by Bisecting Method
To create a tooling direction, bisecting lines are created using the faces that are closely parallel or at positive draft angles to Z direction. Bisecting lines are created by intersecting YZ (X direction)and XZ (Y direction) planes on the Class A Surface. A final bisecting line is created using already generated bisecting lines along their respective planes. This final bisecting line is the Tooling direction.
(a) X direction
The face that is perpendicular to Z direction can be easily cleared, the faces that are closely parallel to Z direction are at a positve draft angle are considered to create a bisecting line. A sketch of YZ plane is considerd and is intersected with Class A Surface. A bisecting line generated using the faces that are at a positive draft angle w.r.t Z direction.
(b) Y direction
The face that is perpendicular to Z direction can be easily cleared, the faces that are closely parallel to Z direction are at a positve draft angle are considered to create a bisecting line. A sketch of XZ plane is considerd and is intersected with Class A Surface. Here, only one face exists, therefore, to create a bisecting line, a line is created that makes an angle of 5degres w.r.t Z direction and is considered as a bisecting line.
(c)Tooling Direction
The tooling direction is obtained by bisecting the above two bisecting lines.
3) Draft analysis
Draft analysis is performed on Class A surface to obtain the Main Tooling Axis. Materials option in customize view should be active before performing Draft analysis. Click on Draft analysis, a color code variant dialog box appears displaying colors, green for positive draft angle, the nominal draft angle for industrial applications is 3 deg. Therefore, 3 deg is provided, the red color indicates a draft angle between 3 and 0. The blue color indicates a negative draft angle.Click on the the compass option on the dialog box , click on the compass and drag it and align it onto the bisector, now click at any point on the surface. The entire surface on topside appears green, this indicates that all the faces can be cleared easily and the bisector created can be considered as the Main tooling axis.
Draft Analysis on CLASS A SURFACE
The Draft analysis on class A surface with color code variant can be observed from the figure
Draft Analysis on SOLID BODY or PLASTIC COMPONENT
It can be observed from the figure that all faces that are green in color are cleared with a draft angle of 3 deg, the faces with red color are with a drft angle in between 3 and 0.
The faces with red color possess a draft sngle of 2.97 deg. Therefore, providing a draft angle of 2.97 or less could clear the faces in red.
It is evident from the above figure that all faces are cleared with a draft angle of 2.97deg.
Views of final plastic component
Isometric view
Top view
Front view
Left side view
Right side view
