Challenge

Week 8 - Challenge 2 - Switch Bezel Design

Aim: To create the Switch Bezel Plastic component through the given Class-A surface.

Tooling axis:

The axis is the direction in which the mould opens or else the core and cavity opens. The tooling axis should help to clear component from core and cavity, so it plays a very crucial role in plastic designing and manufacturing also.

Draft Angle:

Draft angle is the degree of taper that is incorporated into the side wall and part, core and cavity of the die cast tool to aid in the removal of a part. Primarily, they function to reduce the friction between the part and the tool as it is ejected. Without draft angles, parts can be stripped, dented, or get stuck in the tool.
Draft angle also reduce the friction between the part, core and cavity and also reduce the production time as it is easy to reject the part from the core and cavity.

Draft Analysis:

As the name suggest, draft analysis is nothing but checking the draft angle range i.e, whether the angle is in the ideal range of 3 degrees or not.
In this analysis we have a colour scale where we can see the range of a specfic color and we can even change the range by souble clicking on the number.
To do draft analysis go to insert-Analysis-Featured Draft analysis

Tree Structure:

Close surface feature:

Publication:

Publications are used to publish the Geometric set which can be directly accessed.
To do Publications, go to Tools-Publications as shown below we can do publications.

Steps to create a tooling axis by using bisecting method:

First of all, check all the directions of the component to find the best tooling axis direction and in the given component the Z direction is the best where no interfere in clearing the tooling axis.
Create a point on the Surface of the class A and Create a line which acts as a dummy axis.
Using plane command create planes along YZ plane and ZX plane and the screen looks like the below screeshot.
By using intersection command create intersection line along YZ plane.
Create two lines by using the line command along the points of the line of two faces.
Create a bisecting line with the help of the line which are created earlier.
By using intersection command create intersection line along ZX plane.
Create a line by using the line command along the points on line over the faces in ZX plane.
Create a random line sketch along the point and the line angle with the above created line will decide the angle of the final tooling axis for now take it as 3degree and create a bisecting line for the sketch line and above line.
Take the bisected line as reference and do draft analysis after draft analysis it shows an error that means the draft angle is not in the desired arrange by doing trail and error we found 4.5 degree makes sense.

Steps to do draft analysis by using the feature draft analysis option:

Check with Feature Draft analysis option in insert>Analysis>Feature Draft Analysis
In Feature Draft analysis select the compass and place the compass on the tooling axis and select the class A surface then in the Draft analysis we can clearly see the surfaces draft angle with respect to the tooling axis there we can find the colour representation also.
We can change the range of the colour also as per the plastic design rule the draft angle is 3.
We can find the respective screenshots down below.

Screenshots of the Draft analysis report for both the given Class-A surface and the final plastic component:

Screenshots of the solid model with the proper color code of the draft angle in various orientations (Isometric, Front, Side, and Top View):

Conclusion:

Hence all the submission requirements are successfully done and the CATPart file is attached below using Browse option.

Ship work like this
in your own course.