Week 8 - Challenge 2 - Switch Bezel Design

AIM: Create the Switch Bezel Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. 

 objective: 

• Tree Structure
• Ensure Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set 
• Use the Close Surface feature to make a solid body from the surface. 
• Publications: Use the publication option and publish the below
  • Tooling Axis
  • Class A, B, and C surface

Introduction:

CLASS-A SURFACE: the class-A surface is used in the automotive design industry. it describes the final production surface data for the aesthetic parts.

CLASS-B SURFACE: the class-B surface is the second surface that has a certain thickness from the class-A surface. this surface contains engineering aspects of a model. These must be smooth and "error-free" as well but are not held to the standards that class A surfaces are.

CLASS-C SURFACE: The Class C finish allows more imperfections than Class A or B. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces.

 Draft analysis:

Draft analysis is required to check if a part has required draft or not. Draft is required so that a part can be ejected from its mould.

Design methodology:

Insert the class A surface of thes Switch Bezel in CATIA software. 

Determining the tooling axis for the switch bezel 

Creation of class B surface.

Creation of class c surface.

Join the switch bezel's class A, class B, and class c surfaces and ensure all the surfaces are closed surfaces.

Use the Close Surface feature to make a solid body from the surface. 

finally, Perform the Draft analysis on the switch bezel final plastic component. 

 class A surface :

STEP 1: Check the connectivity of the Class A  Surface

• Ensure that there is no gap between the component, using join command.
• We can visually check it or by clicking boundary command.
• It has 3 boundaries one outer and two inner circle boundaries.

Therefore first check completed.

STEP 2: Find the tooling axis of the component. The tooling axis is nothing but the mould opens or cavity opens.

• Check visaully which is the best possible tooling axis.
• Check all three axis.
• z is the best possible tooling axis.

Creating a Tooling axis along z:

tooling axis are two method:

     1. Bisecting method

     2. Normal to surface

i follow normal to surface method. extract flat surface and create point on flat surface and create tooling axis  direction z 

Now perform the Draft analysis using the Featured Draft Analysis tool in the tools.

Then after opening the draft analysis tool box go for the compass and place the compass alinged to tooling axis and click on the lock symbol after alinging and further click on the surface.

 

Now creating Class B Surface:

Intially extracting the flat surfaces using extract option from Class A surface.

Then perform Untrim option:

Then Offset the surface inorder to get the required thickness:

Then perform Extrapolate inorder to increase the length:

Now trim the surfaces to required surfaces:

Now fillet the surface to required amount:

Now Creating Class C Surface:

   class A surface take boundary and sweep the draft angle

and the last process  trim the class A,B and C surface then get the final product

Now convert solid model 

 In the method closed surface method 

Material:

Duroplast is a composite thermosetting plastic, a close relative of Formica and Bakelite. It is a resin plastic reinforced with fibers (either cotton or wool) making it a fiber-reinforced plastic similar to fiberglass.

It was also used to make suitcases. Duroplast is light and strong. It is made of recycled material, cotton waste and phenol resins. Because it can be made in a press similar to shaping steel, it is more suitable for volume car production than fiberglass.

CONCLUSION:-

    Finally the Class – A, B&C surfaces with the Tooling Direction have been Published and the Switch Bezel is moved on to the designing of the next operation – the creation of B-side features.