Switch Bezel Design

AIM

• To create the Switch Bezel Plastic component through the given Class-A surface.
• 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.
• A solid part should be created out of the closed surface with a thickness of 2.5 mm

PROCEDURE

STEP 1

Load up the given model in the Catia workbench.

STEP 2

Tooling Axis

• First decide the tooling axis direction , here we have only 3 surface. So using sketches, the tooling axis is made.
• Base surface is extracted initially (fig.1), then created a point over it at its center. Then an axis sytem is created on it. (fig.2)
• Then create a positioned sketch on YZ plane.
• Take an intersection of class A. (fig.3).
• Then create two lines on the inclines over the intersection and biscet then to obtain the line. (fig.4)
• Tooling axis for X direction is created (fig.5)

fig.1

fig.2

fig.3

fig.4

fig.5

• Create another positioned sketch on ZX plane .
• Then take a section of class and intersect it. (fig.6) and (fig.7)
• Create a line over the inclined line over the intersection and create a line starting from the center and with 3 deg angle with the first line we created. (fig.8)
• Bisect both the lines to obtain the tooling axis for Y direction. (fig.9)

fig.6

fig.7

fig.8

fig.9

• Next, to create the main tooling axis , bisect the x and y tooling axis to create the main tooling axis. (fig.10) and (fig.11)

fig.10

fig.11

STEP 3

CREATING THE B SURFACE.

• Simplyfy the model by untrimming the surfaces of the component and extrapolate the untrims so that the untrimmed surfaces cuts through each other. (fig.12, fig.13, fig.14)
• Create offsets of each surface with an offset value of 2.5 , which will be the thickness of final model. (fig.15)
• Then trim the untrims based off of the class A's shape.
• Then obtain a final trim of B surface (fig.16)
• finally add fillets to the B surface. (fig.17,fig.18)

fig.12

fig.13

fig.14

fig.15

fig.16

fig.17

fig.18

STEP 4

CREATING THE C SURFACE.

• Extract the boundaries of the class A (fig.19)
• Sweep the extracted curves as guide curve and draft axis as the tooling axis with an angle of 3 deg.(fig.20)
• Extrpolate the sweep surface and trim both the sweeps .(fig.21a)(fig.21b)
• Use smoothcurves to get rid of the patches on the sweep.
• Then join the A surface with C surface. (fig.22)

fig.19

fig.20

fig.21a

fig.21b

C surface

fig.22

STEP 5

FINAL CLOSE SURFACE CREATION.

• After joining the A and C surfaces , join that output with B surface. (fig.23)
• Make sure no boundary is forming after joining all the surfaces (fig.24)
• Final close surface is created .fig(25)

fig.23

fig.24

fig.25

STEP 6

CLOSE BODY CREATION

• Go to part body workbench and using close body command , thicken the component. (fig.26).

fig.26

STEP 7

DRAFT ANALYSIS

• Run draft analysis on the final output .
• Make sure the min draft angle 3 deg is followed.

RESULT

• Created the Switch Bezel Plastic component through the given Class-A surface.
• The tooling axis for the given Class-A Surface is created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.
• A solid part is created out of the closed surface with a thickness of 2.5 mm
• Ran draft analysis on the component and ensured the min 3 deg draft angle is followed.