Week 8 - Challenge 2 - Switch Bezel Design

Challenge 2 - Switch Bezel Design

AIM:- Create the Switch Bezel Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the mode

OBJECTIVE:-

• Creation of Tooling Axis.
• Creation of class B and C surfaces.
• Creating a solid part out of surface modeling.
• Draft Analysis of class A Surface and final plastic component.

CLASS A:- Following Surface is given as the input for the component creation

Creating of Tooling Axis:

• Considering the Ejection from the cavity of the mold after manufacturing the interior trim (switch bezel) must have a nominal 3-degree draft angle.
• Hence the tooling direction is created by considering the above factor and bisecting method is used.
• The base surface of the class – A was extracted and a point at the center is created and an axis system was inserted to the point with the current feature disabled.
• Then, using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
• Then bisecting lines with the two inclined lines were drawn.

• Now the same procedure is done along the xz plane but on one side we don’t have inclined lines so the center point is used to extrude a line along the z-direction and gave a measurement of 5 degrees (Tentatively).

• With these two lines from sketches 1 and 2, the bisecting line is created and published as Tooling Axis(tooling direction)

Creation of Class B Surface:

• For creating the class-B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.
• Then all the surfaces have been extrapolated to get intersections between them.
• Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.
• Finally, the required corners have been filleted to 12.5mm (15mm-2.5mm). [ 15mm - fillet value of the A-surface, 2.5mm – Thickness of the component ]

• Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.

Creation of class c:

• For creating this surface we have to extract the boundary of class A.
• Then by using the sweep command the surface was created with the following feature controls,

Final Trims:

Class A + Class C

To make sure that there is not any open boundary between class A and Class c, we have used the join option to create the single body. This is done to make sure that the parting line doesn't lie between these two surfaces.

Class A + Class B + Class C

For this, we have trimmed the join of the class A and class C Surfaces With Class B.

Then, by defining the part body by using the Closed Surface command in Part Design, the component's solid body is created.

Draft Analysis:

• First the class – A surface is checked before creating the Class –B&C surface and finally the solid body must be analyzed. Both can be done by following the below procedures.
• By changing the view mode to custom view parameters – Material mode then the feature draft analysis is enabled.
• Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locking it.
• Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle.
• The green color area shows that it satisfies the 3-degree draft angle. If not satisfied then by using the Running point tool the area is measured and then altered to get a successful draft for the created tooling direction.

Tree Structure:-