Week 8 - Challenge 3 - Coin Holder Design
Aim: To Create the Switch Bezel Plastic component through the given Class-A surface by creating a required tooling axis.
Introduction
Automotive bezel is a trim or bodywork that surrounds a light, holds the face of an instrument in position, or decoratively conceals gaps between bodywork and components as an escutcheon. Often chrome or plastic.
Procedure for Designing Coin Switch
To start with is to download and open the below class A file of the switch bezel.
Now check the continuity of the surfaces using bounddary option. There should not be not gap between the surfaces.
Tooling Axis / Direction creation:
Once it is verified that there is no gap, next step is to create Tooling axis of the above model. Check visually for the direction of tooling. The should be permissible 3 degree draft angle for the ejection of the part after manufacturing.
The base of the class A surface is extracted and a point at the center is created and axis system is inserted.
Here since the side wall is perpendicular to the bas surface, the normal perdicular line is created as the tooling axis.
As the tooling axis is created next publish it using publication option in tools section.
Class B creation
First thing we have to do is to extract the side wall surface using extract tool 
one by one.
Untrim the surface and extrapolate the walll surface. Trim the wall surfaces as required.
Offset the trimmed surface by 2.5mm thickness towards outside.
Apply the edges fillet to the edges and check for the fiilet dimension by measurng on the class a surface.
Next extract the base surfaces and follow the same procedure as above surfaces created.
Untrim the surface and extrapolate the walll surface. Trim the wall surfaces as required.
Offset the trimmed surface by 2.5mm thickness towards outside.
Next extract the top wall surfaces and follow the same procedure as above surfaces created.
Untrim the surface and extrapolate the walll surface. Trim the wall surfaces as required.
Offset the trimmed surface by 2.5mm thickness towards outside.
Now trim the top wall surface with the base surface as required carefully.
Next extract the outer flange surfaces and follow the same procedure as above surfaces created.
Untrim the surface and extrapolate the walll surface. Trim the wall surfaces as required.
Offset the trimmed surface by 2.5mm thickness towards outside.
Now trim the top wall surface with the base surface as required carefully.
Class C creation:
Extract the class A surface and Class B surface wtih respect to xy axis. In the below image we can see that the the gap between the line is almost perpendicular.
Create the boundary of the class A first.
Nex extract the below surafce which are connected to the class boundary.
Click sweep option for the creation of the surface. Select subtype "With reference surface", give the angle as 90 degrees and length as 3mm.
Extrapolate and trim the created class C surface and class B surface for joining accuractely.
Now join the Trimmed surface with the class A surface.
Now check for the boundary if open edges are there or not.
Since there is no open edges, we can proceed to creating solid.
Open part design workbench and click close surface , select the surface body and click ok.
Steps for Draft Analysis:
Change the view mode to the custom view and select view paramater as Material mode, then the draft analysis is enalbles.
Click the draft analysis option 
, move the compass with the red dot to align with the tool axis.
Now lock the compass and click anywhere on the part, the color will be changed.
Change the value of the green color limit as 3 degrees.
The green color shows that the surface satisfies the draft angle and other color if the angle is not satisfied. This can be corrected by altering the angle and measuring at points to get succesfully draft to get satisfied.
Conclusion:
Finally the Class B and C surface is created and The suface is thickhened with close surface option.
The draft analysis is carried out and satisfied.
Expanded Feature Tree:
Different Views:
