Week 8 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL DESIGN CHALLENGE 2

SUMMARY

--CREATING TOOLING DIRECTION

--STEPS OF CONSTRUCTION

--VIEWS OF PART

--TREE STRUCTURE

--DRAFT ANALYSIS

--CONCLUSION

CREATING TOOLING DIRECTION

• Tool axis controls the orientation of the tool axis that will be used to create the toolpath.
• Tool axis — Select to define the tool orientation. The default value is Vertical, which is used for standard 3-axis machining. However, it can also bea fixed angle or a continuously changing orientation.
• Considering the ejection from the cavity of the mount after manufacturing the interior trim(switch bezel must have the 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 centre is created and an axis system was inserted to the point with the current feature is disabled.
• Then,usingproject intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
• Then bisecting lines with the two iclined lines were drawn
• Now thw same procedures 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 degree (Tentatively).
• With these two lines from sketches 1 and 2, the bisecting line is created and published as tooling axis( tooling direction)

STEPS OF CONSTRUCTION

CONSTRUCTION OF CLASS B

• For creating the class - B surfcae 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 2.5 mm the B- Surface was offset to 2.5mm and the required trim operations must be carried out.
• Finally, the required corners have been filleted 12.5mm ( 15mm-2.5).

CONSTRUCTION OF CLASS C

The required outer edges of the A- surface were extracted using Multiple Extraxt. Then for avoiding the patches the curve is smoothened using the curve smooth option.Then by using the sweep command the surface was created with following feature controls.

• Profile type - line
• Subtype - With Draft direction
• Guide curve - smooth curve
• Draft Direction - Tooling axis
• Draft computation Mode - Square
• Angle - 3 degree
• Angle Sector - Positive Downwaed
• Length - 20mm

Then by using extrapolate command the edges were intersected between the surface corners which eases the trimming operation.Now the required portion of the c - surface were trimmed out.

CONSTRUCTION OF CLOSED SURFACE

Now the class - A and Class - c surfaces were joined together by removing the gaps in between them with the help of extrapolation ( tangent continuity ) and trim surface.Then the exact surface of the switch Bezel was trimmed from the above - resulted trim surface with the class - b surface.Then by defining the part body by using the closed surface command ib Part Design, the component's solid body is created.

3D VIEWS OF SOLID

ISOMETRIC VIEW

FRONT VIEW

TOP VIEW

SIDE VIEW

TREE STRUCTURE

DRAFT ANALYSIS

• First the class - A surface is checked before creating the Class - B & C surface and finally the solid body must be analysed . Both cab 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 redpointer and then lockes 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 colour area shows that it satisfies the 3 degree draft angle. If not satisfied then by using the Runnind point the area is measured and then altered to get a succesful draft for the created tooling direction.

CONCLUSION

BY USING CATIA V5 THE FOLLOWING PART IS CONSTRUCTED