Week 8 - Challenge 3 - Switch Bezel Design

DESIGN AND DRAFT ANALYSIS OF SWITCH BEZEL

OBJECTIVE:

The main objective is to design the switch bezel, creation of the tooling axis and draft analysis.

PROCEDURE:

Before starting the design of the component we have to check the class-A surface for any discontinuities using the boundary command, this command will specify the boundaries which are not closed in the green colour, if there are any open edges are seen in the class-A surface we have to close the gap, otherwise we can start working.

TOOLING AXIS CREATION

As the first step we have to check the class-A surface if the proper draft is given or not, so we have to create an axis system to create the tooling axis. For creating an axis system we need a point on the surface, so we have to extract the bottom surface and put the point in the geometrical centre by simply entering 0 in the dimension of the point, this steps are shown below

After creating the point we need to place an axis system on that point, we have make sure that we don’t select current option in the axis system.

BISECTING METHOD OF TOOLING AXIS CREATION

In this method the tooling axis is created by bisecting the two lines, this bisecting line needs two lines and a point to create a bisecting line.

Then we have to select plane which intersects the class-A skin and we have to us the intersect 3d elements option to intersect the class-A skin on the plane and make them construction draw two line on the each side of the lines as shown in the picture and now use the bisecting line command and select the two lines to execute the command similarly create the sketch and bisecting line for the other side also in that side we have one face only other face is not present there so we have make a line of our own with a random angle value of 3 degree we can also change the degree if the draft is not achieved, the following images shows the procedure for tooling axis creation.

The above picture shows the creation of the bisecting line using the line command in the reference elements, we need to select the two lines we created on the sketch1 and sketch2 and we have select the line command in the reference element then select bisecting line in the line type, then select the line 1 and line 2 after that select the point and choose the proper direction for the bisecting line, now we can name this bisecting line as main tooling axis and also to change the properties to make it visible and publish it for the ease of access.

For publication of the tooling axis we have to select and rename the line as tooling axis and after that we have to select the Tools drop down publication menu and select ok in the dialog boxes to create the publication.

Now we have created the tooling axis, so we can perform the draft analysis. To perform draft analysis we have to put the customize view parameters mode in the view mode and after entering into customize view mode we have to select the material mode as shown in the below image

Then perform the draft analysis by selecting the draft analysis icon or by selecting Insert-Analyse-Draft analysis, then we have to select the compass icon on the direction tab of the draft analysis tool bar.

And place the compass on the tooling axis by picking and dragging it on the middle point of the compass, after that press the lock icon on the same tool bar, and click on the any of the surface of the part to perform the draft analysis.

In that small colour code dialog box shows the value of the degree and the maximum and minimum values, this values also can be changed by selecting on the colour codes of the small dialog box, here the draft degrees on that part less than 3 degree will be shown as red colour, and below zero is shown as blue colour, and the values above the 3 degree is shown in green colour and it shows that the part can be manufactured and adequate draft is given.

After checking the draft, we have to design the b-surface and c-surface we have to extract the top surface and offset it according to the thickness of the part, un-trim it, extrapolate it.

Also extract the wall surfaces of the class-A surface and un-trim and extrapolate it, also do the same steps for base surface also.

While giving fillet to b_surface we have to reduce the value from the thickness of the fillet, then only uniform thickness of the surface is attained, here the measured fillet value of class-A surface is 14 mm so we have given a fillet value of 11.5 mm.

After extrapolating them trim the wall surfaces with the base and after that trim the top surface with them to create the complete b_surface.

C-surface creation

For the creation of the c-surface we have to extract the edges of the class-A surface with the extract command, select the vertex as edges to apply boundary in the extract, then select the sweep command in sweep command select the second option Line in the profile type, and in sub type select the with draft direction, and select the boundary, and draft direction and give the draft degree as 3, then select the outside direction of the draft then select ok to get the sweep in 3 degree draft angle.

Then join the class-A surface with the C-surface using the join command and inspect for any gaps using the boundary command.

After that trim the b_surface with the joined surface then the complete surface model of the part is made, then we have use the close surface command in the part workbench to make a complete solid body.

After creating the close surface we have to perform the draft analysis for the final product also,To perform draft analysis we have to put the customize view parameters mode in the view mode and after entering into customize view mode we have to select the material mode as shown in the below image

Then perform the draft analysis by selecting the draft analysis icon or by selecting Insert-Analyse-Draft analysis, then we have to select the compass icon on the direction tab of the draft analysis tool bar.

And place the compass on the tooling axis by picking and dragging it on the middle point of the compass, after that press the lock icon on the same tool bar, and click on the any of the surface of the part to perform the draft analysis.

we can also measure the draft angle in the specific area by using the draft under running point icon on the display tab of the draft analysis.

In that small colour code dialog box shows the value of the degree and the maximum and minimum values, this values also can be changed by selecting on the colour codes of the small dialog box, here the draft degrees on that part less than 3 degree will be shown as red colour, and below zero is shown as blue colour, and the values above the 3 degree is shown in green colour and it shows that the part can be manufactured and adequate draft is given.

CONCLUSION

Thus the draft analysis for the class-A surface is done, b_surface, c_surface is created and complete part is created by close surface command and draft analysis for the final part is also done.