Week 8 - Challenge 3 - Switch Bezel Design

Switch Bezel

Tooling Axis -

Tooling Axis is the direction in which the component will be ejecting after the molding process is completed

Drafting -

Draft is the inclination given to any particular plastic component's cavity walls in order to achieve easy ejection, once the process is completed

Procedure

1)Closed surface of Class-A Surface:

create the boundy line to ckech the class A surface is closed or not

Use join Command from the Operations Toolbar to join these surfaces together

2)Creation of Tooling Axis:

The Tooling axis was decided along Z- Direction considering its selection rules mentioned above

Next we created an axis system along a suitable point according to the boundary and design of the component ensuring the rules of selection tooling axis direction are not violated

Here we have an unciosed pocket which has to be cleared along the tooling direction

Hence we create a sketch line bisecting two opposite faces of the pocket and another sketch line at a certain angle to the one remaining face (say 3 deg ) which can be changed according to the draft analysis

Bisect the two lines in order to create the Tooling Axis

3)Draft Analysis Of Class-A Surface:

Before starting the draft analysis ensure that the 'Materials' option is selected under Customize View Parameters in order to view the results of the analysis

Draft analysis window will be opened having three sections - Mode, Display and Direction

In the Display section select the compass and drag it onto your component Place it along the tooling axis

Lock the direction of the draft

Assign the lower limit as 3 deg to the Green range from the value edition dialogue box

Once you do it, click on the component to see the results

You can also check the draft value at any point using the 'Analysis under running point' option in the Display Section

4)Creation of B Surface:

To simplify the process, we extracted the simpler surfaces using the Extract Tool in Operations Toolbar

The extracted surface offset is created with offset distance equal to the thickness of the component

Further we untrim the offset surfaces using Untrim Tool and extend them to a certain suitable value using Extrapolate intersect each other

Using the Trim Tool we trim them to a single continuous surface

Finally we provide necessary fillets and the B-Surface is created.

5)Creation of C Surface:

We create the boundary of the Class-A Surface using the Boundary Tool

Using the Sweep Command we sweep the boundary along the tooling axis as the draft direction

Then we extrapolate the faces using the Extrapolate Tool

lastly we trim the class-a surface and the sweeped surfaces along with the holes using trim command to form the C+A surface

6)Creating a closed surface and forming a solid part from it:

Use the Trim Tool to form a closed surface from B-Surface and C-Surface

Create a solid part from this closed feature using the Surface based feature inpart workbench

7)Draft Analysis of Solid Part:

Before starting the draft analysis ensure that the 'Materials' option is selected under Customize View Parameters in order to view the results of the analysis

Click on Insert >> Analysis >> Feature Draft Analysis

Draft analysis window will be opened having three sections - Mode, Display and Direction

In the Display section select the compass and drag it onto your component Place it along the tooling axis

Lock the direction of the draft

Assign the lower limit as 3 deg to the Green range from the value edition dialogue box

Once you do it, click on the component to see the results

You can also check the draft value at any point using the 'Analysis under running point' option in the Display Section

Switch Bezel Views:

Conclusion:

We have successfully created a Switch Bezel using given Class A Surface