Week 8 - Challenge 2 - Switch Bezel Design

OBJECTIVE:-

objective of project is to design the switch bezel and do a draft analysis for it by creating the required tooling direction with the help of Bisecting Line method.

INTRODUCTION:-

The switch bezel is the frame part of the window switch that holds its switch covers and buttons into place. Moulding is the method used for manufacturing of the plastic trims by most OEM’s, hence by considering the manufacturing regulation the switch bezel is designed.

DESIGN CONSIDERATION:-

• Class – A surface should be aesthetically smooth and look good.
• Class – B surface might have all the supporting features like ribs.
• Class – C surface should also pass the draft analysis.
• Parting Line must be coincide with the B surface since flashing couldn’t affect the aesthetic of Class A

PROCEDURE TO CREATING CLASS A SURFACE:-

• First, the given styling surface is inspected for any irregularities and if found any, then it is need to be corrected by using Trim, Extrapolate, Split and Join commands.
• The Class A surface has some irregularities shown in below figure.

CREATING TOOLING AXIS:-

• Consider the Ejection from the cavity of the mould, after molding the switch bezel must have the nominal 3° degree draft angle.
• Hence the tooling direction is created by considering the above factor, and bisecting line method is used.
• The base surface of the class – A was extracted and a point at the centre is created and a co-ordinate system was inserted to the point.
• Then, using project intersection along yz plane is created and the two inclined lines were drawn using the positioned sketch.
• Then bisecting lines with reference to 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 centre point is used to extrude a line along the z-direction and gave a measurement of 5 degrees.
• With these two lines from sketches 1 and 2, the bisecting line is crated and published as Tooling Axis(tooling direction).

CREATION OF CLASS B SURFACE:-

• For creating the class-B surface, surface required 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 and we trimmed it.
• Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset value will be 2.5 mm and the required trim operations must be carried out.

• To get the radius of fillets the filleted surface is extracted and untrimmed the surface and then the redius is measured using measure item command.

CREATION OF CLASS C SURFACE:-

• The required outer edges of the A-Surface extracted using Multiple Extract. for avoiding the patches the smooth curve is used.
• Then the surface is created using sweep command.
• 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.

CREATION 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 in Part Design, the component's solid body is created.

DRAFT ANALYSIS:-

CONCLUSION:-

Finally the Class – A, B and C surfaces with the Tooling Direction have been designed.