Week 8 - Challenge 3 - Switch Bezel Design

Aim: plastic trim of Class A, B, and C surface for given styling surface into close surface profile with respect to tooling direction using plastic manufacturing standards.

Objective:

• To design switch bezel as per automotive OEM standards.
• Create class B, Class C and Tooling Direction.
• Converting close surface into the solid part of 2.5mm thickness.
• Perform draft analysis to verify the creation of tooling axis.

Class A Surface:

Procedure for Tooling Axis:

1. Reference point is created along the surface zero and new axis system created.
2. Then intersect is created with plane for the creation of lines between surfaces.
3. Two lines then bisected and tooling line is created.
4. The tooling direction defines the direction of class C swept surface.

Creation of class B surface:

1. The class B surface is created by extracting surfaces of class A and the untrim them.
2. After this offset of 2.5 mm created and extrapolated surface is used where ever required to perform Trim Operation.
3. Surface trim is used to give required shape of B surface.

Creation of class C surface:

1. For creation of Class C surface, boundary is extracted from class A surface using Multi extract.
2. After this sweep option is used along the tooling direction to create class C Surface.

Closed surface creation:

1. Class A and Class C surface joined together.
2. After this, joined surface and class B surface trimmed together to create closed surface.
3. By using closed surface command in part workbench solid plastic design has been made.

Draft Analysis:

1. Go to insert <Analysis< feature draft analysis
2. Click on the compass icon and align it with the tooling axis and click on the surface, we will get our result.

Green Color represent all surface of body meets minimum 3-degree draft angle and red face represent less than 0-degree angle of draft which act as core side in injection molding assembly. In my case there is one blue color face which is 2.2-degree for this reason we may need to change draft angle or class A surface for easy removal of from mould.

Feature Tree:

Conclusion:

Hence plastic trim surface is achived for switch Besel Design and verified using draft analysis and measured of uniform thickness across the body to meet the plastic manufacturing standards.