Week 8 - Challenge 3 - Switch Bezel Design

Introduction

In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality. Although strictly, it is nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, many people interpret class A surfaces to have G2 (or even G3) curvature continuity to one another (see free form surface modeling).

Class A surfacing is done using computer-aided industrial design applications. Class A surface modellers are also called "digital sculptors" in the industry. Industrial designers develop their design styling through the A-Surface, the physical surface the end-user can feel, touch, see, etc.

A common method of working is to start with a prototype model and produce smooth mathematical Class A surfaces to describe the product's outer body. From this, the production of tools and inspection of finished parts can be carried out. Class A surfacing complements the prototype modeling stage by reducing time and increasing control over design iterations.

Class A surfaces can be defined as any surface, that has styling intent, that is either seen, touched or both and mathematically meets the definition for Bézier.

• Automotive design application
• Product design application
• Aerospace design application
• Clay modeling
• Notable software

Creating B & C Surfaces with the reference of Class A Surface.

Class-A Surface: The top-most surface which is the present exterior of the component is said to be a Class-A Surface

Class-B Surface: The Surface which is interior to the component is said to be a Class-B Surface.

Class-C Surface: The Surface which joins the Class-A & 8 Surfaces is our Class-C Surface

PROCEDURE

1. Create a sketch on the ZY plane and the Switch Bezel to create a reference tooling axis.
2. Create a sketch on the ZX plane and the Switch Bezel to create a reference tooling axis.
3. From the above two reference axis, Bisect the lines to create the TOOLING AXIS.
4. Draft analysis for the Switch Bezel by quick analysis mode.
5. Draft analysis for the Switch Bezel by Full analysis mode.
6. Draft analysis for the Switch Bezel in Isometric view.
7. Draft analysis for the Switch Bezel in Front view.
8. Draft analysis for the Switch Bezel in Side view.
9. Draft analysis for the Switch Bezel in Top view.
10. Class B surface WALLS after extract, Surface Untrim, Extrapolate, Trim.
11. Class B surface SWITCH BEZEL ARMREST after Extract, Offset, Surface Untrim, Extrapolate, Trim.
12. Class B surface SWITCH BEZEL BASE after Extract, Offset, Surface Untrim, Extrapolate, Trim.
13. Final Class B surface.
14. Final Class C surface.
15. Draft analysis for the Switch Bezel by quick analysis mode.
16. Draft analysis for the Switch Bezel by Full analysis mode.
17. The final surface of the Switch Bezel with 2.5mm thickness.
18. The final surface of the Switch Bezel with Close Surface.

CONCLUSION:-

• A detailed report is been done explaining the draft analysis and the tooling axis creation.
• An explanation is been given on the way of creating the tooling axis by Bisecting method.
• Screenshots of the Draft analysis report.
• Image of the complete Draft analysis.
• Images of the color scale variant.
• Screenshots of the model with the proper color code of the draft angle in various orientations (Isometric, Front, Side, and Top View.

class A

tooling axis

Class A draft analysis

class b surface after untrim , extrapolating and trimming

class c before trimming

closed surface

solid body / switch bezzel

fillet value checking

final draft analysis