Week 8 - Challenge 3 - Switch Bezel Design

SWITCH BEZEL DESIGN

Aim-To create the switch bezel plastic component through the given class-A-surface and at the end performing the draft analysis on the model.

Objectives-

• To ensure proper tree structure is followed.
• Geometrical sets should have a proper name based on the sketches present inside of it.
• All the sketches should be created under geometrical set.
• Use of the close surface feature to make a solid body from the surface.
• To publish the tooling axis ,Class A,B and C surface.

Procedure-

First import the class A surface of switch bezel model in CATIA V5.

Check the connectivity of class A surface using boundry option.

Ensure that there is no gap between the two surfaces.

Tooling Axis- Now we need to create the tooling axis for the base bracket model. Visually check which direction is better for creating tooling axis. Now in order to create the tooling axis in Z-direction, first create a reference point on any surface as shown in figure.

Now using the reference point create a line in Z-direction. This line will give us the tooling axis.

Creation of Class B Surface-

Consider the thickness of the component as 2.5 mm. Now we need to create a B surface which will be similar to the A surface at an offset value of 2.5 mm.

In this operation we are creating a class B surface in 3 different geometrical sets.

First we are creating a class B surface we need to extract the class A surface as shown in below figure.

Once the surface is extracted untrim it and then extrapolate it by a required value on each side using continuity. Now offset it by 2.5 mm.

Similarly we need to extract the walls and base surface of the switch bezel in different geometrical sets and perform similar operation on it as mention above.

Once all the surfaces are created trim these surfaces to form a class B surface.

Give the appropriate fillets to form Class B surface.

Creation of Class C surface-

To create a class C surface ,first extract the boundaries of the Class A surface and give them smooth curve as shown in figure below.

Now using the sweep option to create the class C surface.

Trim surfaces-

After creation of Class A, Class B and Class C surfaces, we need to join Class A and Class C surface to form a new surface. Then trim the joined surface with Class B surface to form the final required surface.

Isometric view

Front view

Top view

Now using the close surface option from part workbench form a solid body.

Draft Analysis- To perform draft analysis on the switch bezel model ,first set the view parameters to Material mode.

To give the draft direction use the compass and align Z-axis of it with the final tooling axis for the switch bezel model. Once it is properly aligned, lock the daft direction. Select the switch bezel and it will show us the current draft angle of the model.

Class A Surface Draft Analysis

Solid Body Draft Analysis

Full mode analysis

Design tree structure