Week 8 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL

OBJECTIVE: To design switch bezel as per automotive OEM Standard.Create B Class and C Class and tooling axis.Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.Performing draft analysis to verify the creation of the Tooling axis and C Class surface.

SOFTWARE:

• CATIA V5 (Generative Shape Design)

PROCEDURE:

Insert the class A surface of the 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.

CREATE TOOLING AXIS :

The ejection from the mold after manufacturing the interior trim must have the nominal 3-degree draft angle.

hence the tooling directions created by considering the above factor and bisecting method is used.

The base surface of the class-A was extracted to create a reference point on the surface using the point, create a line in the z-direction and an axis system was inserted to the point

then using projection intersection along the yz plane is created and the two inclined lines were drawn inside the positioned sketch.

then bisecting lines with the two inclined lines were created.

Now the same procedure is done along the xz plane but on xz plane, we only have one surface line so the center point is used to extrude a line along the z-direction and gave a measurement of 6 degrees. from the surface line.

Bisecting these two lines sketch1 and sketch2 the bisecting line is created and published as a tooling axis.

DRAFT ANALYSIS ON 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-C SURFACE CREATION:

The edges of the Class-A surface are extracted using the multiple extracts and then converted into smooth curvature to avoid the patches.

Sweep operation is performed (with draft direction) selecting the smooth curves as the guide curve and tooling axis as the direction and draft angle as 3deg

join class-A and class-C surfaces. Make sure that there is no unnecessary boundary present, if there is then increase the merging distance to not more than 0.003mm. and even after there is some unwanted boundary, extrapolate class-A by a small distance and trim it with class-c instead of joining them.

Then trim the class-C surface with the class-B surface.

THE CLASS-C SURFACE

Go to the part workbench by using the Close Surface feature we created a solid body from the surface.

Switch Bezel Final Plastic Component:

DRAFT ANALYSIS OF FINAL PLASTIC COMPONENT:

Following the similar steps performed for draft analysis of class-A surface, we obtained the following result

The draft analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

by selecting the tooling axis, class A class B and class C surface publish it by going to menu bar> tools> publication. this will be published under the publication tab in a tree structure.

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

FEATURE TREE :

RESULT:

Switch Bezel plastic component using class-A surface successfully created and performed the draft analysis on the class-A surface and final plastic component.