Week 8 - Challenge 3 - Switch Bezel Design

DESIGN OF CLASS A, CLASS B AND CLASS C SURFACE OF SWITCH BEZEL USING CATIA V5

Aim:-

• The aim of this project is to develop the product design of the switch bezel with the help of the class A surface followinng the OEM standards.

Introduction:-

Class A:-

• Class A surface is the term mainly used in automative design industry, it describes the final production surface data for the aesthetic parts of the car.

Class B:-

• Class B surfae is the secondary surfaces which is not visible normally, these must be smooth and error free as well but are not held to the standards that class A surfaces are.

Class C:-

• Class C surfaces are the backside surfaces that can have tool marks, flash and other imperfertions without hurting apperance, function,etc..
• The steps involved in creation of this project are:

1. Bringing the class A surface of the switch bezel on Catia v5 software.

2. Determining the tooling axis for the switch bezel.

3. Creation of class B surface.

4. Creation of class C surface.

5. Joining all the class A,class B and class C surfaces of the switch bezel.

6. Building closed surface after joining all the surfaces.

7. Draft analysis on the switch bezel.

Procedure:-

• Below picture is about the surface A which is incorporated in catia V5 workbench.

• Determination of tooling axis on class A surface (SKETCH):-

Creation of Class B surface:-

• The class B surface is created by extracting each surface of class A surface and then untriming them.
• After this an offset of 3 mm is given in the downward direction to generate the class B surface.
• The surfaces are then extrapolated with a certain distance in order to create cross section among the surfaces to perform trim operation.

• Surface trim tool used to trim unnecessary surface.

Creation of class C surface for switch bezel:-

• For the creation of class B surface, first the boundary of the class A surface is extracted using Multiple extract feature.
• After this sweep option is used to create the sweep along the tooling axis direction.

• Class B and Class C surface are joined togrther thwn we get the shape which we want.

• After the operation ,Class B and Class C surface are trimmed together to give the plastic product in a mould shape.

• After complete the procedure, used closed surface tool to convert surface model into solid.

Draft analysis:-

• After completing design draft analysis on component.

• After draft analysis is done we can observe that the green colour shows that the drafted walls of the Switch bezel are above 29 degrees which is a permissible criteria to manufacture in injection moulding.

Detailed tree structure for the creation of switch bezel is represented below.

Conclusion:-

1. Class A, Class B and Class C surfaces are created following standards of automotive industry using Catia V5 software.

2. Draft analysis was performed on the switch bezel and it was observed that draft was under permissible limit for the manufacturing of the component using injection moulding process.