Week 8 - Challenge 2 - Switch Bezel Design

Switch Bezel Report

Aim:

• To create Tooling axis and Conduct Draft analysis for both the Class A and Final Solid part.

Objective:

Switch Bezel

• To create the Final Solid Part by using the given Class A.
• To create the Tooling Axis for the Class A and Final Solid Part.
• To Draft analysis the obtained Final solid part and Class A using the created Tooling Axis.

Introduction

Tooling Axis

• The Tooling Axis is to show in what direction does the core and cavity moves.
• It also created to give a draft angle for the final solid part.

Draft Analysis

• The draft analysis is done on the basis of the Tooling Axis in order to find whether the final product is done as per the Design rules.
• The Draft angle which is assigned to the Tooling Axis defines the analysis.
• The Nominal Draft angle for the plastic product is 3 degree.

Class A

• Class A is the aesthetic surface.
• Class A is created on the basis of a concept sketch or by the predefined shape on basis of the design engineer and customer requirement.
• Class A is given to the Product design engineer in order to get the final solid part.

Class B

• Class B is the surface that is created by the product design engineer in order to get the final product from the class A surface.
• Class B is created based on the thickness that the final solid part should be.
• In other words, Class B is an Extended version of Class A with some thickness gap between them.

Class C

• Class C is the surface that is designed by the product design Engineer.
• Class C is created inbewteen Class A and Class B in order to connect them.

Procedure:

Class A

• The class A is taken as given Catpart file.
• Created class A is checked with the boundary tool.

Tooling Axis

• The tooling axis is created using bisecting method.
• Bisecting method is one method for creating the tooling axis where tooling axis created by intersecting two line.
• The axis is created by extrectin the surface and creating a point on the surface.
• The two line, one line is created from the intresect of created y-axis and class A.
• The second line is from intresect of created z-axis with class A.
• Then orginal tooling axis created.

Draft Analysis on Class A

• The draft analysis is done on class A with the help of tooling axis.

Class B

• The class B is created by offsetting the derived Class A to 2.5mm.
• The Faces of class A is Extracted and untrimed sperately.
• It is done seperately due to fillet that will not be proper when offset.
• The untrimed faces are offseted.
• The trimed together and Edge fillet operation done.
• Thus the class B is derived.

Class C

• The class C is created from the class A using the sweep.
• The boundary of class A is taken.
• Then 'with draft direction' is selected in the sweep tool.
• The tooling axis is used for draft direction and boundary as profile.
• The Class C is created.

Final operation

• The Created class C is joined with the class A.
• The joined class A and class C is trimed with class B.
• If class A and class C join can't be trimed with class B then extrapolate the class B to some millimeters.

Solid Body

• The solid body created by using closed surface.
• The design which created is switched from 'genrative shape design' to 'part design'.
• Then closed surface tool is used to convert the plastic design model to solid form.

Draft analysis

• The draft analysis on solid body is done.
• The draft analysis show the created solid is done as per design rules.

Structural Tree Images

Conclusion

• The Design model stafies all the design rules and the draft analysis.
• The publication and the draft analysis images are provided.