Week 8 - Challenge 3 - Switch Bezel Design

AIM: Creating the Switch Bezel Plastic component through the given Class-A surface of 2.5 mm thickness with the tooling axis meeting the requirements of the draft angle and at the end performing the Draft analysis on the model.

PROCEDURE REQUIRED DRAFT ANALYSIS:

STEP 1: Ensure there is no gap between the two neighboring surfaces.

Operations>Boundary>definition>select component

STEP 2: Tooling Axis: The tooling axis is the direction in which mold or core and cavity are opened.

We have to check all possible tooling directions in all three axes. When we are deciding the tooling axis we have to make sure that all the faces should be visible to that tooling axis, no face should be hidden.

For this component, Z-axis will be the best tooling axis as we can see all the faces of the component and can be cleared in the x and y-axis direction.

STEP 3: To make a tolling axis we have to follow the following steps

• Multiple extracts the base surface
• Pace a point in between of the surface > Point definition > select surface > Distance 0 mm.

STEP 4: Pace the axis system on that point.

STEP 5: Sketch for tooling axis along the Y direction.

STEP 6: Sketch for tooling axis along the X-direction.

STEP 7: Extract tooling axis along the Y direction

STEP 8: Extract tooling axis X direction

STEP 9: Bisect tooling axis X and Y to get the Component tooling axis.

STEP 10: Rename, change color and give thickness to the tooling axis so that it can be easily identified.

STEP 11: Publish Tooling Axis and Switch Bezel Component.

Select this two in model tree>Toolbar>tools>publication>ok

PROCEDURE FOR DESIGN:

STEP 1: Extracting Surfaces from Bezel arm surface.

• Extract the surface
• Untrim that extracted surface
• Offset it inside to 2.5 mm

STEP 2: Extracting Surfaces from Bezel Wall.

• Extract all three surface
• Untrim that extracted three surface
• Extrapolate all three surfaces till they intersect with each other.
• Offset it inside to 2.5 mm
• Trim the surfaces as required in the component.

STEP 3: Extracting Surfaces from Bezel base surface.

• Extract the surface
• Untrim that extracted surface
• Extrapolate the surfaces till they intersect with the wall offset surface.
• Offset it inside to 2.5 mm

STEP 4: Extracting Fillets from Bezel surface.

Extracting fillet surfaces and Untrim them will help us to know the exact value of the fillet radius

• Extract few fillets
• Untrim that extracted surface
• We get to know that the fillets are 14mm and 15mm.

STEP 5: Change the color of the offset surfaces

STEP 6: Trim the offset surfaces as required in the component.

• We can see the surfaces of the component after trim as below -

STEP 7: Give edge fillet radius of 15mm actual radius in addition with 2.5mm of the thickness of the component.

STEP 8: Give edge fillet radius of 14mm actual radius in subtraction with 2.5mm of the thickness of the component.

• We can see the surfaces of the component after fillet as below -

NOTE: Measure the surface to a surface thickness of B surface and A surface with the help of vernier caliper it should be 2.5 mm throughout between the surfaces.

STEP 9: Extract the tangential boundary from one side of the A surface.

STEP 10: Extract the tangential boundary from the other remaining side of the A surface.

STEP 11: Smooth both the lines to avoid seeing the patches on the surfaces.

STEP 12: Sweep one boundary with sweep with direction panel.

STEP 13: Sweep another boundary with a sweep with a direction panel.

STEP 14: We can see the gap between the two sweep surfaces. We can fix this by following the steps.

• Extrapolate all four free edges to a few millimeters.

STEP 15: Trim the extrapolated surfaces as required in the component.

STEP 16: Join the final trim (swept surfaces) and A surface.

• We can see the C surface after joining as below -

STEP 17: Trim C surface and B surface to get thicken part.

• We can see the thicken C surface after trimming as below -

STEP 18: Switch to Part Design Workbench, Define Part body to make Switch Bezel C Surface into a solid component by the surface panel.

PROCEDURE TO CHECK DRAT ANALYSIS: Check draft analysis on the final part body.

STEP 1: Changing view mode to the material.

View mode>view mode customisation>tick material>ok

STEP 2: Calling Draft Analysis.

Toolbar>Insert>Analysis>Feature Draft Analysis

STEP 3:

• Drag the compass from the draft analysis box on the tooling axis and place it properly.
• Click on locks so the compass will get locked to the tooling axis.
• Click anywhere on the component.
• Click OK.
• Analysis of the color of the failing and passing surfaces.

If a component is showing in a Green color that means our component is ready for manufacture.

NOTE: If we find zero degree or negative degree filing color, we can fix it by changing the draft angle, sweep direction, modifying properly tooling axis, etc.

DRAFT ANALYSIS ON A CLASS SURFACE :

LEARNINGS :

• Extracting tooling axis by sketch.
• Inserting Axis system and Publication
• Extract, Untrim, Extrapolate, Offset, Trim, Joining the surfaces.
• Giving Fillet radius to inside and outside Offset surfaces.
• Extracting Tangential Boundary.
• Smoothing Boundary.
• Sweep with a direction panel.
• Joining A and C surface and trimming it from B surface to get the required thicken body.
• Draft Analysis and fixing errors.