Week 8 - Challenge 2 - Switch Bezel Design
- Week 8 - Challenge 2 - Switch Bezel Design
- OBJECTIVE:-
- 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 model.
- Take the Thickness of the component to be 2.5 mm
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- Different views of the MODEL:-
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- Consideration while designing the model:-
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The distance between each point of the edges of two neighboring patches must comply with the following limits:
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For class A: no more than 10 µm = 0.01 mm
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For class B: no more than 20 µm.= 0.02 mm
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For class C: no more than 50 µm.= 0.05 mm
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The angle between the tangents to the surface on the edges of two neighboring patches must comply with the following limits:
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For class A: no more than 6’ = (0.1◦).
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For class B: no more than 12’ = (0.2◦).
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For class C: no more than 30’ = (0.5◦).
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(Note:- ( ’) _means minute:- (ex. conversion of minute to degree: - 6’ = 6/60 = 0.1 degree)
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- Expanded tree view with model construction steps:-
- CLASS-A SURFACE INPUT AND BOUNDARY CHECK
- FILLET RADIUS CHECK OF CLASS A SURFACE
- TOOLING AXIS.
- DEFINITION:-
- Tooling axis:- “ main tool axis” is the axis that defines the mold opening direction.
- Tooling axis must be created on a feature like a hole, slot, cut out, etc, flat surface, or continuous surface of a Class A Surface.
- The tooling axis justifies the angle sector of the side wall draft ”C-surface”, that is the positive angle of the C surface in the direction of the ejection, “i.e. it creates a relation of the component from mold opening to the ejection of part”.
- The tooling axis must be created in such a manner that gives the ejection clearance and mold opening clearance such no undercut will come in the way during ejection and mold opening,
- it also provides the reference axis to the slider axis or angled pin axis, which is used for the undercut inserts, (known as the undercut at an angle of tool axis),
- It is practiced while designing mold tools, that the ejection pins - straight action form pins must be constrained to move parallel to the tooling axis.
- Straight action form pin these pins are ejection pins used to release the Internal undercuts”,
- similarly, sliders are used to release the external undercut.
- METHODOLOGY:-
- Creating an axis system by taking point on a surface of base in class A surface which is a flat surface
- creating dummy axis-1 in YZ Plane by sketching a bisecting curve _(i.e axis in YZ plane)
- creating dummy axis-2 in XZ Plane by sketching a bisecting curve _(i.e axis in XZ plane)
- creating main tool axis "TOOLING AXIS" by BISECTING LINE (i.e bisection of curve from YZ & XZ PLANE, created before)
- B-SURFACE
- C-SURFACE
- CLOSED-SURFACE
- CLOSED-SURFACE CHECK
- ALL SURFACES VIEW
- SOLID BODY:- from a closed surface
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- DRAFT ANALYSIS:-
- DEFINITION:-
- The Draft Analysis enables you to detect if the part drafted will be easily removed “EJECTED”
- the analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values”
- DRAFT ANALYSIS COMPASS:-Terminology
- DRAFT ANALYSIS OF CLASS A SURFACE.
- DRAFT ANALYSIS OF SOLID BODY.
- DETAILED DRAFT ANALYSIS.
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- RENDERED VIEWS OF THE MODEL:-
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