Week 8 - Challenge 2 - Switch Bezel Design

Objective:

The objective of the project is to design the switch bezel and to do a draft analysis for it by creating the required tooling direction with the help of bisecting method.

Design Procedure:

Initially, the class A surface was checked for any irregularities and then it is corrected using trim, extrapolate, split and join commands. After that the tooling axis created.

Tooling Axis:

• 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 centre 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 centre point is used to extrude a line along the z-direction and gave a measurement of 5 degrees.
• With these two lines from sketches 1 and 2, the bisecting line is created and published as tooling axis.

Creation Class B Surface:

The necessary surfaces, minus the offset surface, were extracted in order to create the class-B surface, which was then completely untrimmed.

The intersections between all of the surfaces have been obtained through extrapolation.

because the switch bezel is 3mm thick.

Creation of Class C Surface:

Multiple Extract was used to extract the A-necessary surface's outer margins. The curve is then smoothed using the curve smooth option in order to avoid the spots. The surface was then formed by using the sweep command. The extrapolate command crossed the margins with the surface cornices, making the trimming process easier. The necessary section of the C-surface was now removed.

Class C Surface is Used to join Class A surface and class B surface and make a closed surface.

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.

Draft analysis of Class A Surface

Draft Analysis of Solid Part

Final Part: