Week 8 - Challenge 3 - Switch Bezel Design

Objective: To create class B & C surface for the given class A surface using Catia V5R21 and to perform feature draft analysis.

Procedure:

1. Obtain Class A surface from styling team and perform connectivity check using boundary command.

2. To perform draft analysis for the given class A surface, tooling axis must be created. Tooling axis can be created by extracting the surface and creating a point over it.

3. Create an Axis system at that point.

4. Create a plane with reference to the YZ axis.

5. Use intersection curve command and select all the surfaces and select the plane to obtain intersection curve along Y-direction.

6. Extend the lines of the intersection curve using point to point line command and next create a bisecting line by selecting those extended lines and point.

7. Rename the line obtained from the bisecting line and create another plane along ZX axis.

8. Use intersection curve and create the intersection curve along X axis.

9. To obtain dummy tooling axis along X-direction, a sketch must be created along the plane ZX.

10. Use bisecting line and obtain the dummy axis along X-driection.

11. By selecting the both dummy axis along x&y directions create a bisecting line at the point and rename the line as the Tooling Axis.

12. For easy reference publish the class A surface and tooling axis(line).

13. Perform fetaure draft analysis for class A surface. It is clear that one of the surface does not have the minimum angle required for manufacturing, which can seen in red colour. Since it is a class A surface designers donot have permission to edit it, so this surface is called for verification by the styling team. If in case it is not possible to edit by the styling team too then we have to change the angle accordingly so later part we will be changing the angle between the line along ZX axis and surface to 9.5deg to compensate the draft analysis.

14. For creating class B surface extract base of the switch bezel.

15. Untrim the extracted surface.

16. Extract the walls of the switch bezel in the new geometrical set and name it as walls.

17. Untrim the exrtacted walls of the switch bezel and extrapolate them.

18. Trim the extrapolated surfaces.

19. Extract the base of the switch bezel in the new geometrical set which is named as base.

20. Untrim it and extrapolate the base extract.

21. Offset all the surfaces with a distance of 2.5mm.

22. Trim the surfaces to the required shape.

23. Apply fillets to the surfaces.

24. With the help of multiple extract, extract the edges of the class A surface.

25. Use sweep command and select the draft direction as tooling axis and create class C surface.

26. To remove those small patches which makes difficulties while manufacturing use the smooth curve for the both multiple extracts and replace them with the newly created smooth curves.

27. To remove the gaps between the surfaces, extrapolate them and trim the surfaces for providing a closure between them.

28. Join the class A & C surface and perform a boundary check.

29. Trim the class B surface, by selecting join and B surface using trim command.

30. Enter into part design module and use close surface command to convert the surfaces into solids.

31. Perform feature draft analysis for the whole component.

Views of switch bezel:

Feature Tree Diagram of Switch Bezel:

Conclusion:

Class B and C surface were created for the given class A surface with the engineering standards using catia V5R21 and performed draft analysis and also published them at the end.