Week 8 - Challenge 2 - Switch Bezel Design

TOOLING AXIS, DRAFT ANALYSIS & PLASTIC COMPONENT CREATION OF DOOR ARM REST

OBJECTIVE: The main aim of this challenge is to create the Door arm rest Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface and to create B-Surface, C-Surface from Class-A surface and perform draft analysis for both Class-A surface and the plastic component created.

Taking the Thickness of the component to be 2.5 mm

Tooling axis: The direction in which the mold or core and cavity opens is the tooling axis.

STEP-01

Connectivity of Class-A surface:

Checking the connectivity of the surface, this can be done by creating boundaries or by simply using the join option such that any openings can be easily visualized.

STEP-02

Analyse visually for the best possible tooling axis.

A Dummy tooling axis will be directly created using point-direction command.

Checking possibilities (clearances) in all the directions of axis and find what are the problem creation parts of the component or model.

The clearance checking along all the axis direction will be done by creating an intersection along an axis on a plane with the model and constructing two lines contact with the walls, the line bisecting the two lines and passing through the point will be the tooling axis.

Creating intersection and Tooling axis for checking along Y-Axis:

Using the intersection, lines will be created along the inclined walls, these lines are used for creation of tooling axis by bisecting method where the two lines and point will be selected as inputs.

Creating intersection and Tooling axis for checking along X-Axis:

Using the intersection, lines will be created along the inclined walls and as there is only one wall another line will be created at a certain angle to the wall, these lines are used for creation of tooling axis by bisecting method where the two lines and point will be selected as inputs.

Tooling Axis creation:

Using the tooling axis created along x and y-axis, these tooling axes are used for creation of tooling axis by bisecting method where the two lines and point will be selected as inputs.

Publication:

Publication is used to make easily accessible of the published components.

Draft Analysis:

Draft analysis is done after determining the tooling axis, draft analysis is used to check whether the minimum draft (3 degrees) is maintained or not.

Compass is used to define the draft direction.

If the minimum draft 3 degree is provided the whole component changes in to green colour.

Class-B surface:

Class-B surface is created by extracting each walls and un-trimming and extrapolating the walls to obtain the shape by trimming the excess surfaces and offsetting it to certain distance based on the thickness of the model and giving fillets wherever it is necessary. The offset surface will be the B-Surface.

C-Surface:

The surface created using the sweep option by sweeping the boundaries of A-surface along the tooling axis to connect from A to B-surface is called C-Surface.

Using the B and C Surfaces a closed surface will be formed by trimming the excess surfaces.

The final trim surface will be converted in to a solid model using Closed surface option.

Draft Analysis of plastic component:

The views of the model: