Week 8 - Challenge 3 - Switch Bezel Design

STEP 1: CONNECTIVITY OF CLASS-A SURFACE

• First check the connectivity of the given surface or component
• This is done by creating boundaries or by using Join command
• Ensure that there is no gap between surface connection

• From this image we can see the boundary inside the surface, it indicates there is a gap.
• To solve this gap, use join option to merging the gap (use merging value as 0.003)

STEP 2: TOOLING AXIS CREATION

• First visually analyse the possible direction of Tooling direction.
• Create dummy tooling axis for possible dolling direction.
• Using the Intersection command create intersection line for all X,Y,Z axis direction.

Inter section of Y direction:

Inter section of X direction:

• If we have a surface with one sided wall, then create a opposite wall with own.
• Make angle contraint for this line with wall.

• Bisecting these X,Y directions tooling axis, the main tooling axis will create, Where the two lines and one point will be selected as inputs

STEP 3: B-SURFACE CREATION

• B-surface creation is done by offsetting class-A surface to required thickness.
• Offsetting class-A surface with fillets are more complicated, so go with extract and untrim the surfaces.
• Extract the all the sketch or surfaces used to create object and Untrim it.

Untrim:

• Extrapolate the surfaces till interact each relative surfaces.

• OFFSET it into required thickness of part
• Trim the surfaces to get proper surface without fillets, then fillet it.

FILLET

STEP 4: CLASS-C CREATION

• Create the boundary around the given Class-A surface.
• If this boundary has more surface, then split it into two or more boundary around the surface.

• Here the boundary has lots of intermidiate joints, this create gap while sweeping.
• To clear this joint make smoothening the curvaure.

• Now sweep the boundary with direction of tooling axis.
• This sweeping area is the thickness of the Class-C surface.

• Make extrapolate the sweep area to attain the intract with Class-A and Class-B surface if required.
• Do trim operation sweep area with both class-A&B surfaces.

After done Trimming operation the finel Class-C surface created.

• For make it solid use close command on Part workbench

STEP 5: DRAFT ANALYSIS

• Draft analysis is done after determine the tooling axis.
• Ensure weather all the surface angles are more than 3 degrees along with tooling axis direction.
• There are some colour codes are used to easily determine the angle value

• If the whole angle is more than 3 degrees, then surface colour turned into Green for one type scale and for another scale it has 5 colour variation.
• Here our surface area has more than 3 degrees.

• Below 0° angle indicated by red in colour, these are has negative angles.

STEP 6: PUBLICATION

• Create publication for Tooling axis, Draft analysis and B&C-surface creation

TOP, FRONT, SIDE & ISOMETRIC VIEW OF AN CLASS-C SURFACE: