Switch Bezel Design

Aim - Create the Switch Bezel Plastic component through the given Class-A surface.

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Class A Surface:

This is the given class A surface which is used to create the class B and C surfaces.

Tooling Axis:

The first step in creating the other surfaces is the construction of the Tooling Axis.

• Extract the base surface from Class A surface:

• Create a point on the extracted surface using the point command:
  
• Create a new axis system using the above point as the origin and create an intersect of the y-z plane and the Class A surface:
  
• Create two lines from the edges of the surface which are symmetrically at an angle to each other:
  
• Create a line bisecting these two lines and name as 'Tooling Clearing y direction'.
  
  
  
• Repeat the same steps with the x-z plane and the Class a surface and create a line, passing through the same point and at an angle to the upper edge. Rename the line as 'Tooling clearing x-direction:
  
• Create a new line bisecting the tooling clearing x and y-direction. This new line is the tooling axis which is coloured for easy visualization:
  

Publishing:

• Go to Tools and then Publishing:
  
• Select the Class-A surface and the Tooling axis to publish.
  
  
  

Class B Surface:

• Class B Surface is created using the Class A surface.
• Extract the different surface in class A (except the fillets) and rename them appropriately.
• Untrim the individual surfaces.
  
• Extrapolate the above surfaces using curvature continuity and point continuity:
  
  
• Trim the surfaces together to get a single surface resembling the Class A surface.
  
  
  
• Provide fillets on the edges the same as in Class A surface:
  
  
  
• Create an offset of 2.5 mm of the above surface to get the Class B surface:
  
  
  

Class C surface:

• Extract the boundary of the Class A surface using point continuity:
  
  
  
• Use the Curve Smooth command to smooth the extracted boundary using the curvature continuity and a maximum deviation of 0.001mm (in to prevent any cusp in further steps).
  
  
  
• Use the sweep command to sweep the smooth boundary at a draft angle of 3 degrees with the tooling axis:
  
  
  
• Extrapolate the above surface using the point continuity. The obtained surface is Class C surface:
  

Final Trims:

• The Class A and C surface have a gap in between because of the smoothening boundary curve. This can be removed by extrapolating the Class A surface.
  
  
  
• Now we can trim the Class A and Class C surfaces together.
  
  
  
• Finally, trim the above surface and Class B surface together.
  
  
  The final surface of the Switch Bezel is generated.

Solid-Body:

• The Close Surface feature can be used to create a solid body from the above surface.
  

Draft Analysis:

• For the draft analysis, we need the solid body and the tooling axis.
• Firstly customize the view parameter to change the mesh shading to the material.
  
  
• Go to Tools `->` Analysis `->` Feature draft Analysis
  
  
• Choose the Compass from the above dialogue box and drag-and-drop it on the Tooling Axis.
  
  
  
• Choose the solid body as the Element:
  
  
  
• The green region has a minimum draft of 3 degrees and the blue region has a negative draft (this is because of the reverse direction). There is no cyan region on the body which indicates that there is no region with a 0-degree o draft.