Week 8 - Challenge 2 - Switch Bezel Design

Aim:

To 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 draft angle requirements and performing the draft analysis on the model at the end.

Operation to do:

1. Create Tooling Axis.
2. Create Draft Analysis for Class A Surface.
3. Create Class B Surface.
4. Create Class C Surface.
5. Create Final Product.

Material used in Switch Bezel:

• Acrylonitrile Butadiene Styrene (ABS)
• Nylon 6/6. its unreinforced state, it is an extremely rigid, abrasion-resistant, heat-resistant and hard material.

Where is it used?

• The control panel bezel is the frame part of the window switch that holds its switch covers and buttons into place.To decide the tooling axis, component is observed for optimum direction.

Followed Constrains:

• The change in dimension of the Class A Surafce is not allowed.
• Change in thickness is not allowed.

Tooling Axis:

• First I have tried using the plane which having more visibility of the surface and I had choosed the z plane and i tried over it but it affects in the part of draft analysis.

Image of the method I have tried

• So, I choosed another method. The tooling axis for this component will be created from normal to surface. The shoud be done using the method of extracting the plane surface and Creating a point in the plane using point on the surface. And fiinally the line shoud create using the normal to surface.
• It can be done using the bisecting method also.

Class A Surface:

• Class A Surfaxce is a scaned model or the model which is already drawn is given for further process. It describes the final production surface data for the aesthetic parts of the car. The term 'Class A' is often misunderstood, but it's generally seen as the 'Holy Grail' of surface modeling. This is the outer layer of model.

Draft Analysis:

• The draft analysis technique is used to analyze whether our part model created in CAD is manufacturable based on the draft condition applied. Here the part should get easily removed from the panel dies (in case of Sheet metal part) or Mold (in case of plastic). The analyse shows whther the angle given in the surface is upto the level or not. This can be identify by using the Green, Blue and Colour. Green means to perfect (< 2.9deg), Blue (0deg), Red (> 2.9deg).

DRAFT ANALYSIS OF CLASS A SURFACE

DRAFT ANALYSIS OF OVERALL SURFACE

Class B Surface:

• This is the surface followed by Class A Surface. It is the inner surface of the model with some thickness. The fillet and offset of the Surface shoud given according to the Class A model. The flash from the molding process shoud not come in the surface of the Class A, so the Class B design shoud not distrub the class A Surface.

Class C Surface:

• Class C Surface is the surafce which join both the class A & B uisng the boundary, trim, join method. 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 which the Customer feels do not need to meet a high cosmetic.

Final Product:

• Final product includes the finished surface of Class A, Class B and Class C. Having the complete surface model of the Switch Bezel.

FINAL TRIM

Solid Surface:

• After the completion of the final trim it shoud be change to the Close surface.

FINAL OUTPUT

FAMILY TREE