Challenge

Week 8 - Challenge 2 - Switch Bezel Design

IImtiyaj Mathakiya15 Sept 2022

DESIGN AND DRAFT ANALYSIS OF SWITCH BEZEL

Aim:- Create the Switch Bezel Plastic component through the given Class-A surface.

Objectives:-

To create class B & C surface for the given component.
To form the tooling axis and capture the surface properly.
To check the feasibility of the component with a draft of 3 degrees.

The objective of the project is to design the swith 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 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:-

Class – A surface should be aesthetically smooth and good.
Class – B surface should have all the supporting features like ribs.
Parting Line should coincide with the B surface since flashing couldn’t affect the aesthetic of Class – A.
Class – C surface should also pass the draft analysis.

CREATION OF TOOLING DIRECTION:

Considering the ejection from the cavity of the mould after manufacturing the interior trim must have the nominal 3-degree draft angle.
Hence the tooling direction is created by considering the above factor and bisecting method is used.
The base surface of the class-A was extracted and a point at the center is created and an axis system was inserted to the point with the current feature is disabled.
Then using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
Then bisecting lines with the two inclined lines were drawn.
Now the same procedure is done along the xz plane but no one side we don't have inclined lines so the center point is used to extrude a line along the z-direction and gave a measurements of 5 degrees.
With these two lines from sketches 1 and 2,the bisecting line is created and published as tooling axis.

CREATION OF CLASS-B SURFACE:

For creating the class-B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.
Then all the surfaces have been extrapolated to get intersections between them.
Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.
Finally, the required corners have been filleted to 12.5mm (15mm-2.5mm). [ 15mm - fillet value of the A-surface, 2.5mm – Thickness of the component ]

BAZEL REST SURFACE.
WALL
BASE
B SURFACE TRIM
EDGE FILLET 1&2

BAZEL REST SURFACE.

WALL.

Base.

B SURFACE TRIM. FINAL B SURFACE.

CREATION OF CLASS C SURFAC:

The required outer edges of the A-Surface were extracted using Multiple Extract. Then for avoiding the patches the curve is smoothened using the Curve Smooth option.
Then by using the sweep command the surface was created with the 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 Downward (1)
Length – 20mm

Then by using extrapolate command the edges were intersected between the surface corners which eases the trimming operation.
Now the required portion of the C – surface were trimmed out.

MULTIPLE EXTRACT 1&2
SWEEP 1&2
CURVE SMOOTH 1&2
EXTRAPOl 1,2,3&4
TRIM 1,2&3

FINAL JOIN.

FILLER VALUE.

CREATION OF CLOSED SURFACE:

Now the class – A and Class- C surfaces were joined together by removing the gaps in-between them with the help of extrapolation(tangent continuity) and Trim surface.
Then the exact surface of the Switch bezel was trimmed from the above-resulted trim surface with the class-B surface.
Then, by defining the part body by using the Closed Surface command in Part Design, the component's solid body is created.

PROCEDURE FOR DRAFT ANALYSIS:

First the class – A surface is checked before creating the Class –B&C surface and finally the solid body must be analysed. Both can be done by following the below procedures.
By changing the view mode to custom view parameters – Material mode then the feature draft analysis is enabled.
Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked it.
Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle.
The green colour area shows that it satisfies the 3-degree draft angle. If not satisfied then by using the Running point tool the area is measured and then altered to get a successful draft for the created tooling direction.