Week 8 - Challenge 3 - Switch Bezel Design

 SWITCH BEZEL DESIGN

Creating tooling axis

1. Two sketches are created on the XZ and YX planes.
2. The surface and respective plane intersection is got in the sketch using Intersect 3D Element command
3. In the sketch in the XZ plane we create 2 lines on the intersected surface boundary and bisect them to get the tooling direction in the XZ plane
4. In the sketch in YX plane we create a line on the intersected surface boundary and a line from the origin at an angle of 6degree from the initial line, this line acts as tooling axis in this plane
5. For getting the main tooling axis for the Bezel switch we bisect the tooling directions from the two planes.

xz plane

yz plane

main tooling axis

Creating class B surface

1. The faces from the class A surfaces are extracted
2. These extracted faces are untrimed and extrapolated
3. They are then offset by the thickness value of the final part
4. The surfaces are then trimmed to create the shape of the Bezel switch
5. Finally the fillets are applied and the class B surface is formed

class B surface

Creating Class C surface

1. The boundary of the Bezel switch are extracted in two parts.
2. The extracted boundaries are swept with draft direction which is the Tooling axis and with a draft angle of 3°
3. Since the edges of the swept surfaces did not meet at a point, we extrapolate the edges of both the sweeps and trim them to form the final class C surface
4. The C surface is then joined with the class A surface
5. The joined surface is then trimmed with the class B surface to create the surface body of the Bracket
6. This surface body is then turned into a closed surface to make the final body of the Bracket.

class C surface

class C and class A surface joined

final surface body

Closed body

Draft analysis of the closed body

Report

• From the draft anaysis, the faces in green have a draft angle of 3degree or greater
• The faces in blue have a draft angle between 0 to 2 degrees
• While the faces in red have negative draft angles, which need to be corrected