Week 8 - Challenge 3 - Switch Bezel Design

DES5GN AND DRAFT ANALYSIS OF SWITCH BEZEL

OBJECTIVE

The objective of the project is to design the switch bezel and do a draft analysis for it by creating the required tooling direction with the help of Bisecting method

INTRODUCTION

The control panel bezel is the frame part of the window switch that holds its switch covers and buttions into place.Moulding is the method used to manufacture the plastic trims of an automotive by most OEM'S hence by considering the manufacturing consideration the switch bezel is designed

DESIGN CONSIDERATION

• Class-A surface should be aesthetically smooth and good
• Class-B surface should coincide with the B surface since flashing couldn,t affect the aesthetic of Class-A
• Parting line should coincide with the B surface since flashing couldn,t affect the aesthetic of Class-A
• Class-C surface should also pass the draft analysis

PROCEDURE FOR CREATING THE SWITCH BEZEL

• First,the given styling surface is checked for any irregularities and if found any then it is corrected by using Trim,Extrapolate,Split and join commands.
• The below image shows that the Class- A surface is clean and no irregularities present ,so lets move on the next step.

CREATION OF TOOLING DIRECTION

• Considering the ejection from the cavity of the mould after manufacturing the interior trim(awitch bezel) must have the nominal 3-degree draft angle.
• Hence the tooling direction is created by considering the above factor and bisecting method is used.
• The base surface of the class-A was extracted and a point at the centre is created and an axis system was inserted to the point with current feature is disbled
• Then using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
• Then bisecting lines with the two inclined lines were drawn
• Now the same procedure is done along the xz plane but on one side we dont have inclined lines so the centre point is used to extrude a line along the z-direction and gave a measurement of 5 degrees
• With these two lines from sketches 1 and 2 the bisecting line is created and published as tooling Axis.

CREATING OF CLASS-B SURFACE

• For creating the class-B surface the required surface except the offset suface have been extracted and then untrimmed all the surface
• Then all the surface have been extrapolated to get intersection betweemn them
• Since the thickness of the Switch bezel is 2.5mm the B-surface was offset to 2.5 mm and the required trim operatipons must be carried ourt
• Finally the required corners have been filleted to 12.5mm(15-2.5)

CREATING OF CLASS-C SURFACE

• The required outer edges of the A-surface were extracted using Multiple extract.Then for avoiding the patches the curve is smoothened using the Curve Smooth option.
• Then by using the sweep command the surface was created with the following feature controls

1. Profile type- line
2. Subtype-with Draft Direction
3. Guide Curve-Smooth Curve
4. Draft direction-Tooling Axis
5. Draft Computation Mode-Square
6. Angle-3 Degree
7. Angle sector-Positve Downward
8. Length-20mm

• Then by using extrapolate command the edges were intresected between the surface corners which eases the trinning operation
• Now the required portion of the C - surface were trimmed out.

CREATION OF CLOSED SURFACE

• Now the class-A and class-C surface were joined together by removing the gaps in between them with the help of extrapolation and trim surface
• Then the exact surface of the switch bezel was trimmed from the above resulted trim surface with the class-B surface
• Then by defining the part body by using the closed surface command i paret design,The components solid body is created.

PROCEDURE FOR DRAFT ANALYSIS

• First the class-A surface is checked before creating the class-B & C surface and finally the solid body must be analysed.Both can be done by following the below procedures.
• By changing thge view mode to custom view parameters-Material mode then the feature draft analysis is enabled.
• Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked it.
• Then by selecting the quick analysis mode the nominal value will be 3 degree and checked for the components draft angle.
• The green coplour area shows that it satisfies the 3 degree draft angle.If not satisfied then using the running point tool the area is measured and then to get a sucessesful draft for the created tooling direction

CONCLUSION

Finally the class-A,B & C surface with the Tooling Direction have been published and the switch Bezelk is moved on to the designing of the next operation-the creation of B-side features.