Week 8 - Challenge 3 - Switch Bezel Design

SWITCH BEZEL DESIGN

The main objective is to create a tooling axis for a given switch bezel by satisfying the construction of surfaces and to perform draft analysis to check if the part has given draft to the surfaces which are lying parallel to the tooling axis. Also, to create CLASS B and CLASS C surfaces from the given switch bezel to create the solid part with proper draft standards.

DRAFT :

In engineering, draft is the amount of taper given to the surface of molded or cast parts perpendicular to the parting line.

The in build draft analysis tool used in CATIA to ensure that the faces are taper with the respect to the tooling axis. The tooling axis is the direction of mold part ejection.

The draft is provided on both core and cavity sides of the parts, which are produced using molding, to reduce damage to the surfaces during ejection.

Usually the draft angle should be 3 degrees.

CREATION OF TOOLING AXIS

Check for open gaps

Create a point on the base of the switch bezel and with respect to that point create an intersection of YZ plane with the surface.

Create the bisecting line in same sketch

Create dummy tooling axis along y direction

Bisect the both lines to create the tooling axis

publish the tooling axis and CLASS A

DRAFT ANALYSIS CLASS A SURFACE

The draft analysis is created on CLASS A. We have observed from the below images that all surfaces are green indicates that they have draft angle of minimum 3 degrees.

CLASS B SURFACE CREATION

un trim the bezel rest surface

Take the walls un trim, extrapolate

Extract the base, un trim it and extrapolate it

Offset all surfaces by 3 mm

Trim the unwanted surfaces

Apply the required fillet value

CLASS C SURFACE CREATION

Extract the boundary of CLASS A surface and smoothen it

Swept the two curves with draft direction

Extrapolate the edges and trim un necessary

Join CLASS A and CLASS C

Trim the joined surface with CLASS B surface

Check for open gaps (no open gaps found)

Close the surface

DRAFT ANALYSIS ON PLASTIC PART

Here the edge having draft angle less than 3 degrees

Change the angle (3 to 3.2) in swept surface and do analysis again also earlier i have taken 6 degrees for y direction tool axis inclination

All surface having prefect draft

Tree structure :

Views of final part :

Conclusion :

The draft analysis is done on the given class A surface of the switch bezel, and it is found that the surfaces are having the minimum draft, and it is suitable for manufacturing. The class B and class C surfaces are created, and a solid part is created from the all surfaces

Thank You