Week 8 - Challenge 2 - Switch Bezel Design

CHALLENGE REPORT:

Tooling axis:

Checked for the feasibility for the tooling direction by looking into the component from all the angles with respect to the 3 perpendicular axes. Found out the axis was directed along the z-axis.

Created 2 dummy tool axis along x and y axes respectively. Dummy tooling axis along the y-axis was made using projection on the side profile and bisecting the side walls. But, dummy tooling axis along x-axis was taken at 6 degrees from the side wall. The tooling axis was created by forming a line bisecting both dummy tooling axes. This tooling axis was created at 2.95 degrees from the side wall.

B Surface:

The B Surface is divided into 3 parts i.e., bezel armrest, side walls and base. 4 geometrical sets have been created for them, which also includes trims and fillets. The bezel armrest is made by extracting upper surface of the class A and untrimming it. This surface is then offset for given distance. The walls are then extracted individually, untrimmed and extrapolated for proper trimming. The obtained trim is then offset. The base is extracted, untrimmed, extrapolated and offset from the class A. The bezel armrest and side walls are trimmed and then trimmed with the base. The entire trim is then given appropriate fillets.

C Surface:

It is created by extracting the side profiles of the class A. As the line was discontinuous, the curves were made smooth using smooth curve command. These curves are then swept at 3 degrees with respect to the tooling axis. The ends were extrapolated to trim the surfaces with each other.

Finally, A and C surface are joined together and then trimmed together with B surface. The obtained surface is converted

Draft analysis:

Draft analysis is carried on both class A and the obtained solid. And the results are shared in the screenshots.

PLEASE FIND THE FOLLOWING FILES:

->CATPart.zip

->Screenshots Draft Analysis.zip