Challenge

Week 8 - Challenge 3 - Switch Bezel Design

Switch Bezel Design

AIM:

To design switch bezel as per automotive OEM Standard.
Create B Class and C Class and tooling axis.
Converting close surface into the solid inside part workbench and provide the thickness of 2.5mm.
Performing draft analysis to verify the creation of the Tooling axis and C Class surface.

TOOLS USED:

Procedure

creating Tooling Axis

A Reference Point is created along with the Surface zero and a new Axis system is created
The X Direction along with the Class A and Y direction along the Class A was used to create the Tooling direction
Finally, the Tooling axis is created by bisecting the two lines and it is published. Class A Surface as input using surface operation commands Class B is developed.

The tooling Axis determines the direction of the Class C boundary swept with draft direction.
When viewing from the tooling direction normal all the parts that are drafted should be visible so it gives a rough idea to determine product manufacturing in Injection moulding.

B Surface Creation

The next step is to design the B surface for the input which is usually the surface where all engineering aspects and support creations are done.
The B surface Creation is performed using surface operations in CATIA which is an offset from Class A with dimension proportional to the thickness of the part.

In the Switch bezel, the B surface is offset 2.5mm from the input which is the thickness of the part

Apply trim to all unwanted parts.
The B surface is extrapolated compared to the A surface and forms the bottom skin of the part.

C Surface Creation

The Next step is to from the C surface which is an intermediate surface between A and B and is used to give the closed surface appearance to the design
The C Surface is swept using the profile as the boundary line of Class A which is the Guide curve with a subtype along the draft direction.

The Direction of the sweep is the tooling direction formed earlier
The draft angle for the sweep operation is provided which is 3 Degree and the surface is swept for length above the thickness of the specified part

The C surface is refined using smooth Curve options to remove the complexity and patches along the swept surface
Finally, the Class A and Class C surfaces are joined together and the convexity of the surfaces should be less than 0.003mm and the surfaces are merged.

Closed Body Creation

The Closed surface is then validated to find the irregularities along the edges and imperfections along the edges were then corrected using operations like extrapolate and surface trim.
This Closed surface is the outer skin of the switch bezel and finally, the part is formed by the Closed Surface in the part design workbench
The final part is measured to validate the uniform thickness of the part, especially along the filleted edges.

Draft Analysis

The part created has to be changed to the material mode in the display frame
Then by enabling compass definition the axis system in pan along the direction of the part and aligned in line with the tooling direction Lock Direction is applied that fixes the compass and then the mode dialogue box is formed by snapping at any point on the part
The Colour Codes are classified and Draft Angle are applied Then the Running point analysis is used to hover around the part to analyse the permissible draft angles and the analysis is saved

Draft analysis of class A

TREE STRUCTURE

FRONT VIEW

TOP VIEW

SIDE VIEW

ISOMETRIC VIEW

Conclusion:

Creation of the Switch Bezel Plastic component through the given Class-A surface is completed and draft analysis is done.

Ship work like this
in your own course.