Week 9 - Challenge 2 - Switch Bezel Design
AIM: To create the Switch Bazel Plastic Components through the given Class-A surface and perform draft analysis on the final plastic component.
Objective:
- Create the Toolling Axis
- Creation of class B and Class C surface
- Creating a solid part out of surface modeling
- Draft analysis of class-A surface and final plastic component.
Thickness of Plastic Part - 2.5 mm
Tool used: CATIA V5
Introduction: In this project we are designing a Switch Bazel using given class A surface. The approach includes creation of Class B surface keeping 2.5mm thickness in mind for the complete component. The design also included Class C creation from the given parent surface.
Constraints:
- No change in Class A are allowed.
- Part thickness can't deviate by more than +- 30%
- All design rules should be strictly followed.
- All surfaces should be closed before converting to solid
- All faces should meet the allowed draft requirements.
CLASS A: Following surface is given as the input for the component creation.
TOOLING AXIS:
First we have to observe and study the class A surface to create the "Tooling Axis" for the component, and for the above given Switch Bazel pocket buttom surface is the best suitable tooling axis. Here we have to create point on surface and then take an intersection of Class A surface horizontally and virtically and then create tooling axis. This is a second method to create tooling axis if there is no hole present in class A surface (alternate method for tooling axis where we use surface for tooling).
Extract the base plane and then create point on that surface and use axis on that point. After that insert new sketch and take intersection of class A surface in middle and same process do in virtically.
Insert sketch and take intersection and draw a line and then create bisecting line
Now we have to create other side bisecting line
Tooling axis
And then publish it
Now we have to create Class-B surface
CLASS B SURFACE:
To create the class B surface, I considered the entire surface has 3 parts 'WALL, BASE REST SURFACE and BUTTOM SURFACE'. If we directly offset the class A surface, fillets may lead to cause an error, to avoid the errors we need to extract the surfaces and untrim the extracted surfaces and extrapolate those untrimmed surfaces with point continuity. Now trim those extrapolated surfaces to the required shape. And finally, fillets were given to the final trim.
BASE RESTARM SURFACE
Offset it by 2.5mm according to the thiclkness of class A surface
Create WALLS
Extract the surface as required and then hide class A surface
Now untrim them by using untrim command
Extrapolate it as per required dimension
Trim it
Offset it by checking the thickness of the Class A surface upto 2.5mm
BASE BUTTOM SURFACE
Extract the base buttom surface from Class A surface
Untrim them
Extrapolate it
Offset it 2.5mm downside
Now we can see that Class A surace and B surface offseted by 2.5mm
Now Insert new geometrical set and name it Class B trimming
Trim 1
Trim 2
Here we maintain 2.5mm offset from Class A surface
Check the fillet value
Here we can see that 25mm virtical radius and 14mm horizontal radius
Apply edge fillet by maintaining 2.5mm thickness on class B surface
Class C Surface:
It is the combination of Class A, Class B and Class C surfaces. To create a class C surface, I used the sweep command by considering the outer boundary of the class A surface. In the sweep command, go to the 'line' command in the 'profile' block and the subtype is 'with draft direction'. Now select the outer boundary and tooling axis, give 3 deg in the angle (the draft angle for a plastic component is 0.5 to 3 deg) and select the direction to sweep, in this condition the class B surface is under the class A surface so select the inside down arrow to sweep. Now I joined all the sweeped surfaces by using the 'join' command and then I trimmed the Class A, Class B and Class C surfaces to make a closed surface, to make a Solid body.
Boundary creation and Sweep command:
Now use sweep command to make class C surface
By the multiple extract we can extract class A boundry
And then use sweep Command
Extracted part convert into smooth curve
Extrapolate it upto 3mm (required dimension)
Trim them
Join surface C with surface A
Now unhide the surface B and trim with surface A & C
Now Check boundry of that whole surface body
Here we can see when final output surface is select it showing error it means there is no gap inbetween.
DRAFT ANALYSIS:
To perform draft analysis, click on Insert>Analysis>Feature Draft Analysis
Once the draft analysis toolbar is opened, go to the display block and select the 'Analysis under the running point' command to check the angle for different sides (walls and inclined plane angles) on the class A surface. The color scale on the bottom visualizes, whether the draft angle meets the requirements or not (3 deg) by indicating the colors Green, Blue and Red. Once the draft angle analysis was done, we need to align and fix the compass to the tooling axis of the class A surface.
To align and fix the compass to the tooling axis, go to the Direction block in the draft analysis toolbar and click on the 'Use the compass to define the new current draft direction option (or just click on the compass symbol). Now bring the compass to the surface and align it to the tooling axis of the class A surface and click on the lock symbol beside the compass in the direction block. Once we click on 'ok' on the draft analysis toolbar, we can finish the draft analysis process.
When we check inclination angle shows 13.225 degree so we have to give maximum 13 degree but here we give 3 degree and when we give 14 degree it shows error in red color and red color show draft angle which is 0-3 degree.
Published the surface A,B and C
Now we have to make it solid body
- Switch to the part design
- Select close surface
TREE STRUCTURE
ISOMETRIC VIEW
FRONT VIEW
TOP VIEW
RIGHT SIDE VIEW
CONCLUSION:
Here we studied surface modeling on SWITCH BEZEl through given input Class-A surface. Through the Class-A surface we create Class-B and Class-C surface and their solid body feature. Also analyse their draft angle and maintain 2.5mm thickness of the surface.
ISOMETRIC VIEW
LINK:
https://drive.google.com/file/d/1xbCn0iJI8CYtxt6JB2B3nVsfv9RjgILn/view?usp=sharing