Week 8 - Challenge 2 - Switch Bezel Design

AIM: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 TOOLING AXIS METHOD and perform draft analysis.

INTRODUCTION:

Switch Bezels in car are parts which contains switches and controls for different functions like Window control, Door lock/Unlock,Media and Temperature controls. Moulding is the method used to manufacture the plastic trims of an automotive.

REPORT-

CONSIDERATION :

• Class – A surface should be aesthetically smooth
• Class – B surface should have all the supporting features like ribs.
• Parting Line should coincide with the B surface since flashing couldn’t affect the aesthetic of Class – A.
• Class – C surface should also pass the draft analysis.

Objective:

• Geometrical sets should have a proper name based on the sketches present inside them.
• All the sketches should be created under the Geometrical set.
• Use the CLOSE SURFACE feature to make a solid body from the surface.
• To publish the Tooling Axis, Class A, B, and C surface.
• Ensure Proper Tree Structure.

DRAFTING ANALSYIS FOR CLASS A SURFACE :

• the mold after manufacturing the interior trim must have the 3-degree draft angle.
• Hence the tooling direction is created by considering the above factor and TOOLING METHOD is used.
• CLASS A BASE is extracted and a point at the centre is created with referance to the base of CLASS A.
• Then, using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
• DRAG THE COMPASS TO THE AXIS LINE AND CLICK DIRECTION .

CLASS A SURFACE:

• Go to insert- analysis- feature draft analysis
• Align the tooling axis with the compass.
• Click on the surface and see that the surface is within the permissible limit of the draft values.
• The surface should be green and in the column nominal value 3deg given as input. hence the draft analysis on the class-A surface is successfully performed.

CLASS B SURFACE:

• For creating the class-B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.
• Then all the surfaces have been extrapolated to get intersections between them.
• Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.
• THEN fillet of 11.5 and 17.5 are given.

Class C SURFACE:

• It is the combination of Class A, Class B and Class C surfaces.
• To create a class C surface, I used the sweep command by considering the outer boundary of the class A surface.
• In the sweep command, go to the 'line' command in the 'profile' block and the subtype is 'with draft direction'.
• Now select the outer boundary and tooling axis, give 3 deg in the angle (the draft angle for a plastic component is 0.5 to 3 deg) and select the direction to sweep, in this condition the class B surface is under the class A surface so select the inside down arrow to sweep.
• The same procedure is repeated for the two circles on the class A surface. Now I joined all the sweeped surfaces by using the 'join' command and then I trimmed the Class A, Class B and Class C surfaces to make a closed surface, to make a Solid body.

OPERATION'S:

• BOUNDARY
• SWEEP
• SMOOTH CURVE'S
• EXTRAPOL
• TRIM
• MULTIPLE EXTRACT
• JOIN

DRAFT ANALYSIS OF CLASS C:

For this analysis, main tooling axis is taken draft reference.

Following results were obtained:

SOLID BODY:

CONCLUSION:

The Design of Plastic Component - Base Bracket from Class A is completed using concepts of Draft angle, Draft Analysis, Tooling Axis, Class B and Class C creation and converting Closed surface to a solid part.