Week 8 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL-REPORT

INPUT:

Take the Thickness of the component to be 2.5 mm

REQUIREMENT NEEDED

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

STEPS FOLLOWED TO CREATE THE COMPONENT

1.Created tooling Axis

Step 1:created bisecting line which bisects side 2 draft angle walls. refer image below

Step 2:Created bisecting line which bisects centre draft angle walls and also draw one approx line for 3 Degree at initial stage.After the final step of draft analysis at class A surface it is finalized at 6 degree for tool clearing.

Step 3:Created the bisecting line which bisects the line step 1 and step 2 .This line is the Main tooling line.Refer image below

  

FINAL TOOLING LINE

2.Using Draft Analysis. checked the draft along the created tooling axis line.

maximum draft and minimum draft for this component is checked at 3,3.7,3.8 at initial step.results below

Result for 3 deg for Class A surface

Result for 3.7 deg for Class A surface

Result for 3.8 deg for Class A surface

From this result, tooling will clear at 3 to 3.7 degree and at 3.8 degree the negative draft starts.

However for plastic component 3 deg would be generally used.minimum would be 0.5 to 1 deg

So considered 3deg as final at initial stage and proceeded

3.Created Class B surface by considering the 2.5 thickness given

CLASS B SURFACE

4.Created Class C surface by considering the 3 degree draft angle calculated using draft analysis

CLASS C SURFACE

5.Combined CLASS A,CLASS B,CLASS C surface and trimmed the extra edges

FINAL SURFACE MODEL

6.Made it solid part

FINAL PART MODEL

7.Draft analysis has performed to verify the initial results at 3 deg

Result for 3 deg for Solid part

In the above images, Side draft 3 degree for arm rest surface is showing in blue colour 

So the draft angle needs to be less than 3 degree.then measured the minimum valve using draft analysis 

At 2.9 degree results below for solid part

Result

Tooling got cleared at within 2.9 to 3 degree 

IMAGES OF SWITCH BEZEL

Result at 2.9 degree

Result at 3 degree