Week 8 - Challenge 3 - Switch Bezel Design

AIM:-

To Create the Switch Bezel Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model.

Take the Thickness of the component to be 2.5 mm

STEP 1: Ensure there is no gap between the two neighboring surfaces.

Operations>Boundary>definition>select component

STEP 2: Tooling Axis: The tooling axis is the direction in which the mold or core and cavity are opened.

We have to check all possible tooling directions in all three axes. When we are deciding on the tooling axis we have to make sure that all the faces should be visible to that tooling axis, no face should be hidden.

For this component, Z-axis will be the best tooling axis as we can see all the faces of the component and can be cleared in the x and y-axis directions.

STEP 3: To make the tolling axis we have to follow the following steps

• Multiple extracts of the base surface
• Pace a point in between of the surface > Point definition > select surface > Distance 0 mm.

STEP 4: Pace the axis system on that point.

STEP 5: Sketch for tooling axis along the Y direction.

STEP 6 :Sketch for tooling axis along X direction.

STEP 7 : Extract tooling axis along Y direction

STEP 8 : Extract tooling axis X direction

STEP 9: Bisect tooling axis X and Y to get the Component tooling axis.

STEP 10: Publish Tooling Axis and Switch Bezel Component.

Select this two in model tree>Toolbar>tools>publication>ok

PROCEDURE FOR DESIGN:

STEP 1: Extracting Surfaces from Bezel arm surface.

• Extract the surface
• Untrim that extracted surface
• Offset it inside to 2.5 mm

STEP 2: Extracting Surfaces from Bezel Wall.

• Extract all three surface
• Untrim that extracted three surface
• Extrapolate all three surfaces till they intersect with each other.
• Offset it inside to 2.5 mm
• Trim the surfaces as required in the component.

STEP 3: Extracting Surfaces from Bezel base surface.

• Extract the surface
• Untrim that extracted surface
• Extrapolate the surfaces till they intersect with the wall offset surface.
• Offset it inside to 2.5 mm

STEP 4: Extracting Fillets from Bezel surface.

Extracting fillet surface and untrim them will help us to know the exact value of the fillet radius

• Extract few fillets
• Untrim that extracted surface
• We get to know that the fillets are 14mm and 15mm.

STEP 5 : Change the color of the the offseted surfaces

STEP 6 : Trim the offseted surfaces as required in the component.

• We can see the surfaces of the component after trim as below -

STEP 7 : Give edge fillet radius of 15mm actual radius in subtraction with 2.5mm of the thickness of the component.

• We can see the surfaces of the component after fillet as below -

Finally Measure the surface to surface thickness of B surface and A surface with the help of vernier calliper it should be 2.5 mm throughout between the surfaces.

STEP 9 : Extract the tangential boundary from one side of the A surface.

STEP 10 : Extract the tangential boundary from the other remaining side of the A surface.

STEP 11 : Smooth both the lines to avoid seeing the patches in the surfaces.

STEP 12: Sweep one boundary with sweep with direction panel.

STEP 13: Sweep another boundary with sweep with direction panel.

STEP 14 : We can see the gap between the two sweep surfaces. We can fix this by following steps.

• Extrapolate all the four free edges to few millimeters.

STEP 15 : Trim the extrapolated surfaces as required in the component.

STEP 16 : Join the final trim (sweeped surfaces) and A surface.

• We can see the C surface after joining as below -

STEP 17 :Trim C surface and B surface to get thicken part.

• We can see the thicken C surface after trimming as below -

STEP 18 : Switch to Part Design Workbench, Define Part body to make Switch Bezel C Surface into a solid component by surface panel.

PROCEDURE TO CHECK DRAT ANALYSIS : Check draft analysis on final part body.

STEP 1: Changing view mode to material.

View mode>view mode customisation>tick material>ok

STEP 2: Calling Draft Analysis.

Toolbar>Insert>Analysis>Feature Draft Analysis

STEP 3:

• Drag the compass from the draft analysis box on the tooling axis and place it properly.
• Click on locks so compass will get locked to tooling axis.
• Click anywhere on the component.
• Click OK.
• Analysis the colour of the failing and passing surfaces.

If a component is showing in Green colour that means our component is ready for manufacture.

If we find zero degree or negative degree filing colour, we can fix it by changing draft angle, sweep direction, modifying properly tooling axis etc.

CORE SIDE DRAFT ANGLE:-

CAVITY SIDE:-

DRAFT ANALYSIS ON CLASS A SURFACE:-

LEARNINGS :

• Extracting tooling axis by sketch.
• Inserting Axis system and Publication
• Extract, Untrim, Extrapolate, Offset, Trim, Joining the surfaces.
• Giving Fillet radius to inside and outside Offset surfaces.
• Extracting Tangential Boundary.
• Smoothing Boundary.
• Sweep with a direction panel.
• Joining A and C surface and trimming it from B surface to get the required thicken body.
• Draft Analysis and fixing errors.

TREE STRUCTURE:-