Week 8 - Challenge 2 - Switch Bezel Design

Design and Draft analysis of a Switch Bezel plastic component.

Aim: To Create the Switch Bezel Plastic component through the given Class-A surface by creating a required tooling axis.

Introduction

Automotive bezel is a trim or bodywork that surrounds a light, holds the face of an instrument in position, or decoratively conceals gaps between bodywork and components as an escutcheon. Often chrome or plastic.

Procedure for Designing Bezel

To start with is to download and open the below class A file of the switch bezel.

Now check the continuity of the surfaces using bounddary option. There should not be not gao between the surfaces.

Tooling Axis / Direction creation:

Once it is verified that there is no gap, next step is to create Tooling axis of the above model. Check visually for the direction of tooling. The should be permissible 3 degree draft angle for the ejection of the part after manufacturing.

For that should create a dummy axis in any direction, here in Z direction.

The base of the class A surface is extracted and a point at the center is created and axis system is inserted.

Now create a sketch using created axis and point. Create the intersection of the class A surface on the plane as below.

Create 2 line as shown and using bisect option Create a bisecting line between the 2 new lines.

Similarly create a bisecting line in a x direction on zx plane. As we know that the draft anlge should be 3 degrees the line from the origin point is created and the angle is given 3 degree from the class a surface.

Create a common bisecting line with the halp of two lines created to obtion a tooling axis.

As the tooling axis is created next publish it using publication option in tools section.

Class B creation

First thing we have to do is to extract the ribs surface using extract tool one by one.

Untrim the surface and extrapolate the walll surface. Trim the wall surfaces as required.

Extract the base surface and follow the same procedure.

Now offset all the surfaces for about 2.5mm inwards.

Hide all the surafce except the offsect surface. Unide the class A suraface to visually chesk the offset surface.

Also trim the edges as required.

Once the surface is trimmed required fillet is applied to the sharp edges (Fillet = outer fillet +/- Thickness ). And change the colour of the surface for better understanding.

Now the class B surface is created and the following is published using publication tool.

Class C creation:

Using multiple extract option extract the outer boundary of the class A surface one by one.

Now the boundaries using sweep surface and select sub type as sweep from draft angle and select the boundaries as first element and tooling axis as the direction. Click ok the surface is created.

Make sure that the draft angle sector is towards the draft direction. Still there will some kinf of roughness on the surfaces swept.

So using smooth curve option select the extracted curve and click ok. Now the sweep will be little smooth.

Replace the extracted curvers with the smooth curves and update the sweep.

Now the class C surface is created and publish it.

Creation of closed surface and solid Body:

Now join the created class C surface with the class A surface.

After that using trim command trim the surface with the class b surface.

Now the surface modelling is done. Next is to thickhen the model in part design workbench using close surface option.

Steps for Draft Analysis:

Change the view mode to the custom view and select view paramater as Material mode, then the draft analysis is enalbles.

Click the draft analysis option , move the compass with the red dot to align with the tool axis.

Now lock the compass and click anywhere on the part, the color will be changed.

Change the value of the green color limit as 3 degrees.

The green color shows that the surface satisfies the draft angle and other color if the angle is not satisfied. This can be corrected by altering the angle and measuring at points to get succesfully draft to get satisfied.

Conclusion:

Finally the Class B and C surface is created and The suface is thickhened with close surface option.

The draft analysis is carried out and satisfied.

Expanded Feature Tree:

Different Views: