Week 8 - Challenge 2 - Switch Bezel Design

Switch Bezel Design & Analysis

Input :Class A Surface

Class B Surface:

Class C surface:

Tooling Axis:

For tooling axis creation Class A surface is first investigated. In plastic product design tooling direction is essential as it decides the direction for separation of mould.

In this Part design we had only 3 walls so we cant diretly use bisecting method we have to draw tooling axis through sketch method and then use bisection along the axis .

1)we will Draw dummy tooling axis along Y direction

2) Then we will Take intersection of class A surface and draw two llines and create bisecting lines

3) For X direction we will again intersect and follow the same method

The two mean line are finally bisected for creation of tooling axis:

Bisecting method is used to find tooling axis using dummy tooling axis this bisecting line will bisect the two lines if they are perpendicular and will show some error if they are parallel this will decide that whether the surface is toolable or not .

Final Tooling Axis

Draft Analysis:

Draft is the angle in which the part is tapered to allow it to release from the mold properly and as the part is cooled it has a tendency to shrink towards the core side of the mold due to this we need to add draft angles.Nominal draft angles is usually around 3 degrees and more than 3 degrees can also be manufactured like 5 degrees but it will unecessarily increase the costing of manufacturing and final product.

Procedure used for draft analysis in Catia cad software:

1) In display frame first we need to change it to material mode

2) Click on insert then analysis and select feature draft analysis

3) Then we will click on compass and and align it with tooling direction.

4) Then we will click on the lock symbol and then click on the surface of the part the colour will change

5) Different color codes are identified and there we can apply draft angle which will reflect us minimum draft angle in green color.

6) We can also have running point analysis on different regions of the part body for permissible draft angle.

Draft analysis report on Class A surface

Minimum Draft value 2.99 degrees

On inversing the draft direction the color changes

Draft analysis report on solid part

Some error in tooling axis creation is creating walls less than 3 degree and its color is blue

so we will put some variation in degree in tooling axis sketches to achieve around 3 degrees in the walls

Now variation done in tooling axis sketches upto 5 degrees gives us this result.

Running point analysis

3 Degrees Draft

PART TREE WITH EXPANDED CONSTRUCTIONS AND PART BODY :

Solid model with the proper color code of the draft angle in various orientations

1) Isometric view

2) Front View

3) Side View

Left View

Right View

4) Top View

Close surface Feature used to make solid body with a thickness of (2.5mm)

Publications: Tooling Axis , CLASS ( A, B & C ) Surface

Final Part Image:

Part body with closed surface