Week 8 - Challenge 3 - Switch Bezel Design

                                                                                                                         SWITCH BEZEL DESIGN

* TREE STRUCTURE

DETAIL REPORT ON SWITCH BEZEL DESIGN

* TOLLING AXIS

First analays the given Class A surface to form a tooling axis direction because its a three sided part. 

 CLASS A MODEL

Create an extract in the base surface & make a origin point on the surface to place the axis system instead of creating a planes in a origin. Its easier to intersect the plane for axis lines.

Then create a positioned sketch to yz plane taking the origin point as a projection point to create a 3D intrsection along yz.

Daw 2 parallel lines along the intersection then create a bisect line for a center axis line for yz direction. Convert the all sketches except center axis line as a construction lines.

Next do another postioned sketch to zx plane to create a 3D intersection for a axis line zx plane. Since its a one side face, Create a line among intersection lines then create a random line in a projection point and constrained the line by giving the angle. The maximum draft angle is 3 degree. It can be adjusted according to part process. 

Next create a bisceting line for yz and xz line for a main tooling axis direction.

CLASS B SURFACE

* TOP SURFACE 

Extract the top surface with no propogation and untrim the surface .

* WALL FACES 

Extract the three faces,untrim and extrapolate all the faces for trim operation to form a solid face.

* BASE SURFACE 

This one we already extracted during the tooling axis creation. So, just untrim and exrapolate and trim with the wall faces.

* FINAL TRIM

Before entering in to the trim feature we need to offset all the faces with 2.5mm to maintain a eqaul wall thickness of the model for joining the Class c surface with Class A.

OFFSET THE SURFACE 

TRIM SURFACE

Trim the wall faces with the base surface next trim with the top offset surface to complete the Class B.

Measure the fillet radius in the CLASS A and apply in CLASS B. 

We measured one of the radius as R14mm another fillet radius showing different values because its not a staright surface looks like a angled. So select the face for extract then untrim them and measure the exact fillet radius . 

So the another radius value is known as 15mm .

CLASS C SURFACE 

For CLAAS C,use the multiple extract to create a boundary lines for CLASS A surface for sweep. Once the multiple extract lines are created replace them with smooth curve to avoid the strip lines in the outer sweep surface.

Create a Sweep on the boundary lines on both sides upper and lower using the draft direction and point the direction towards downward

We found there was a gap in between the sweep1 and sweep 2 , so extrapolate the edges and trim it with class A to form a CLASS C surface.

Next trim the both CLASS B and CLASS C surface to complete the model.

PUBLICATION

Select the CLASS A , CLASS B , CLASS C and Tooling axis as a publication.

DRAFT ANALYSIS

Draft analysis is used to check whether the designed component is safe to manfacture and can be ejected freely from the mould . Go to  insert - analysis - feature draft analysis.

Once the draft analysis is created , move the compass and merge with the main tooling axis to define the tool of the component and its ready for draft analysis. Lock the draft direction once its was merged with tooling axis.

The colour variant shows the angle of the each surface. Maximum draft angle is 3 degree so we need to work on that. Ensure that Class A and Class C are cleared in same color of the analysis . 

Then we have running analys point to measure the angle on each and every face. 

This one shows the full part analysis color variants of the model.

DIFFFERENTIAL VIEWS