Challenge

Week 8 - Challenge 2 - Switch Bezel Design

SSaravanakumar M K15 Jul 2022

Creating the Switch Bezel Plastic component using Catia:

Class A Surface:

The Class A surface is gives is shown in below image:

Procedure:

Step 1 : Connectivity of the Class A Surface

Check the connectivity of the Class A Surface that is to check that there is no gap between the components using the Join command or by visual inspection or also by using the Boundary Command.

Step 2 : Tooling Axis

The Tooling Axis is created using Bisecting Line Method.

Bisecting Line Method:

In Bisecting Line method is that the possiblities or clearance is checked along the direction using the intersection of surfaces along the axis on the plane of the Class A surface and the two lines is created on the intersections walls that is along the inclined walls of the intersections. Then the line is created by using bisecting line option in line command using the two lines and the point created and that line is Tooling axis.

For Creating tooling axis we create the point. The image of point is shown below

Then one intersection and tooling axis is created using along X axis and another intersection and tooling axis is created using along Y axis and then we bisect these two tooling axis and create our main tooling axis.

Creating Intersection and Tooling Axis Along X Direction:

We create the positioned sketch using YZ plane and point.
Then using Intersect 3-D element command for creating the intersection of the Class A surface.
Then we create two line using line command along the inclined walls of the intersection.
Then a line is created by using two line and a point using Bisecting Line command. The image shows below is creating Intersection and Tooling Axis Along X Direction

Creating Intersection and Tooling Axis Along Y Direction:

We create the positioned sketch using ZX plane and point.
Then the Cut section of the Class A surface is created using Cut Part by Sketch Plane.
Then using Intersect 3-D element command for creating the intersection of the Class A surface.
Then we create a line using line command along the inclined walls of the intersection.
Then a line is created by using line command at the point as reference and the angle between the two line is given as 5.54. The image shows below is creating Intersection and Tooling Axis Along Y Direction

Then using these two tooling axis along X and Y we create the main Tooling axis by using Bisecting of Line method. The image below shows the Tooling Axis.

Step 3 : Draft Analysis

Draft anlaysis is done based on the tooling axis. Draft analysis is used to check the Class A is maintained with minimum draft angle of 3 degree.
The Compass is used define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the surface. The image shows that draft analysis of the Class A surface with color scale variant.

Step 4 : Creating Class B Surface

We first create Bezel rest surface by ectracting the surface using Extract command.
Then we untrim the surface using Untrim command.
Then we offset the untrimmed surface by 3 mm as the thickness of the component is 3 mm using Offset command and the offseted surface is our required Bezel rest surface.
Then create Walls of the Class A surface by extracting the surface using Extract command.
Then we untrim the those surface using Untrim command.
Then we increase the length of the swall surface by using Extrapolate command.
Then we trim those surface using Trim command.
Then we offset the trimmed surface by 3 mm as the thickness of the component is 3 mm using Offset command and the offseted surface is our required Wall surface.
Simmilarly we created the Base surface by using similar steps.
Then those three surfaces (Bezel rest Surface, Wall Surface, Base Surface) are trimmed using Trim command.
Then the edges are filleted using Edge Fillet command with radius 11(14-3) mm and 15 mm.
Now the the filleted surface is the Class B Surface.
Thus the Class B Surface is created and the image is given below

Step 5 : Creating Class C Surface

The Class C surface is the connection between Class A and Class B surface.
Then the upper boundary is extracted using Multiple Extract command.
Then these extracted surface is Swept using Sweep command with along draft direction option and draft angle is mentioned as 3dgree and tooling axis as reference.
Similarly Lower boundary surface is cretaed.
Then the upper and lower surface is smoothened by using Smooth Curve command.
Then the edges length is increased by using Extrapolate command.
Then the two extraploated surfaces are trimed using Trim option.
Now the surface obtained is joined with Class A surface using the Join command and Class C surface is obtained. The image shown below is Class C surface.

Step 6 : Final trim to obtain Switch Bezel Plastic component

The last step is triming the Class c surface with the Class B surface.
Then the obtained surface is converted into solid using Close Surface and thus the final Switch Bezel Plastic Component is obtained. The image is shown below is Switch Bezel Plastic component

Screenshots of the solid model:

Isometric:

Front View:

Back View:

Side View:

Top View:

Draft Analysis of the Solid:

Draft analysis is used to check the solid component is maintained with minimum draft angle of 3 degree.
The Compass is used to define the Draft direction.
The green colour shows that the minimum draft angle is provided otherwise blue color is shown to the solid. The image shows that draft analysis of the solid with color scale variant.

Screenshots of the solid model with the proper color code of the draft angle in various orientations: