Challenge

Week 8 - Challenge 2 - Switch Bezel Design

HHisham Ahamed Mp31 Jan 2023

WEEK 8 CHALLENGE-2

SWITCH BEZEL

Aim

To Create the Switch Bezel Plastic component from the given Class A Surface.

Pic.1 (Given Class A Surface)

Steps to perform given task

Create Tooling axis.
Create Class B Surface from class A Surface.
Create Class C Surface.
Create a solid body using close surface command.
Perform draft analysis for given model.

Create Tooling axis:

Class A surface is one which is provided to us, check the connectivity of the Class A Surface ensure that there is no gap between the component, using join command.A tooling axis is created at the center of hole of the class A surface using line definition and point, the tooling axis is nothing but the mold opens or cavity opens.

Create dummy tooling axis by taking any hole or simple structure as reference.
By observing part or component we have to choose direction of drafting. while doing this we have to consider geomety of component. All holes, fillets, chamfer etc have to take in our consideration and we have to choose direction of drafting. In this case we have selected z axis for drafting direction.
For this,we have selected base to create dummy axis. In this hole we have add one point at center of base and from this point we have create axis system and then intersect this axis system along yz axis.
Then, we have to draw two lines from extreme outer two points or from extreme outer line of intersection line. From this newly created lines, we have to create one bisecting line. This line is your first axis line.
Now from Back surface,we have to take projection of first point on rear wall portion. Now in this case we have only one wall here, so its not possible to do intersection here. For this case, we have created one line on upper edge of class a surface as shown in below fig by using position sketch and after that we have created one random line which is passing through projection point. For this line we have given drafting angle as 3 degree along with edge surface line.
From these two newly created axis line, we have to create one bisecting line and this line is actual Tooling Axis.

Pic.2 (Tooling Axis)

Create Class B Surface from class A Surface:

Class B surface is created by extracting the surface from the class A and Surface untrim then offsetting that surface according to the required thickness( which is 3mm from the given part). The extracted surface should be little bigger than the original class A surface which can be done by using extrapolating command which increases the size of the boundary.

Pic.3

Pic.4

Create Class C Surface:

The surface that Joins both Class A and Class B surface is considered to be Class C Surface.It is created by using Sweep command which created a suface according to the selected boundary.Then,It is trimmed according to the thickness of the part or till the B surface using Trim command which cuts the excess or unwanted areas to the selected point.

Pic.5

Pic.6

Pic.7

Create a Solid body using close surface command:

Creating a solid body from the final result that we get after trimming the Class C Surface using the closed surface command which makes a solid surface between the closed surface.

Pic.8

Perform draft analysis:

Draft Analysis

After the conversion of the Closed surface into a Solid Part, it is subjected to Draft analysis to check if the Part can be manufactured using the Molding process and meets all the Injection molding requirements.

For molded or cast parts, the draft angle is the amount of taper perpendicular to the parting line. It is measurable in degrees. Because plastic shrinks and sticks on molding surfaces as it cools, we draft the walls of the plastic part so that it ejects or breaks free from the molding surfaces more easily and without dragging. To reduce the risk of damage to the parts and ensure ejection, a functional injection molding part must have drafts on both the cavity and core sides.It is performed using tooling axis as tooling direction and Minimum draft angle considered is 3 degree.When the value obtained is less than 3 it will be highlighted in red, These regions drafting is impossible .Hence Tooling axis should be changed or additional process is to done to produce the part.