Week 8 - Challenge 3 - Switch Bezel Design

AIM:

To create the Switch Bezel Plastic component through the given Class-A surface 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.

Tooling Axis:
Tooling axis is a direction which defines manufacturability of the part.

Draft Analysis:

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of 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. Most applications require minimum draft angle of around 0.5^o to 1^o, however 3^o draft angles are widely accepted

To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.

Methodology:

Check the Surface

Check the connectivity of the given class A surface with options such as join, Boundary and dis-assemble surface.

Join:

Check the connectivity using join command by selecting the surface as joining elements.

Create Tooling Axis

As we know tooling axis is the direction that mold pulls apart, the tooling axis should be in a way that component completely clears from the mold and also have a very lesser cost of producing it.

• Create a new geometrical set, name it as TOOLING DIRECTION.
• Create an extract of the base surface using multiple extract command.
• Make a point by using on surface as option.
• Create an axis system with that point.
• Create a sketch by intersecting the class A surface.
• Draw lines with two points on the either side of the intersect where tooling axis covers the surface for molding.
• Draw a bisecting line with the above two lines.
• Similarly create a sketch in ZX plane of the axis system.
• Intersect the surface with ZX plane, draw a line which coincides the intersect.
• Draw a line in 5⁰ from the above intersect line.
• Create a bisecting line for both sketch and rename it as TOOLING AXIS.
• Use Publication from Tools> Publications for tooling axis and class A surface for creating a reference to their geometrical entities.

DRAFT ANALYSIS

• Change the view to ‘material mode’ in customize view option.
• To find Draft analysis option, Go to Insert > Analysis > Feature Draft Analysis.
• Select the mode of operation as quick analysis.
• Selection display option using color scale window.
• Use the compass for selecting the tooling axis in draft direction option and select the surface and lock them.
• If the color scale matches the color of the surface, then the component drafted can be easily removed.

Draft analysis of class A surface:

Create Class B Surface

• Extract and extrapolate the surfaces one by one and trim them into a relevant surface and offset the trim to the required thickness.
• Trim the offsets to create the final surface which is offseted 2.5mm from Class A surface in downward direction.
• The above surface after trimming is class B surface, rename the surface as “Class B Surface” and publish them for easy access.

Create Class C Surface

• Class C surface is the join surface of class A and Class B surfaces.
• Create a extracts for the edges of class A surface.
• Use Sweep ‘line’ with ‘draft direction’ and guide curve as boundary created earlier and tooling axis as draft direction in downward direction.
• Use join command to join the surfaces together
• Trim the class B surface with class C surface.
• Publish them for easy access.

Create Close surface

In part design workbench, create a close surface with the final trimmed surface.

Tree Structure:

Different views of the draft analysis:

Isometric view:

Front view:

Side view:

Top view:

Conclusion

Thus, Creating the Switch Bezel Plastic component through the given Class-A surface 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 are done successfully.