Week 9 - Challenge 2 - Switch Bezel Design

Draft Analysis of a Switch Bezel Class A surface:

1. Ensured that there is no surface gap in the given Class A surface; by Visually checking using Join operation preview command and giving merging distance as 0.001mm.

2. Analyzed the component to identify best possible Tooling Direction (Core & Cavity).

Steps to evaluate Tooling Axis:
1. Created a Geometrical Set, named it Tooling Axis.
2. Created a point in the middle of a base surface. And created a axis system at the created point on the base.
3. Identify faces that may obstruct the free ejection of component. Then, created a positional sketch with YZ-plane as reference and point1 as projection point.
4. Then, took an intersection along YZ-plane using intersect 3D elements tool.

5. Drawn two lines coincident to the opposing faces along the YZ-plane. Made the Intersect and the two lines as construction geometry.
6. Drawn a bisecting line that is equidistant from the two drawn lines along inclined faces in step 5 and passing through point1.
7. Then, created another positional sketch, with XZ plane as reference and point1 as projection point.
8. Repeated the intersect step along XZ plane. And drawn a line coinciding the only face intersect that is available.

9. Also, as there is no face on opposite side, created a line through the Point1 at a 3 degree angle to the line in step 8.

10. Then, created a bisecting line from line in Step 8 & 9.

11. Now again created a bisecting line from line in Step 6 & 10. And named it as tooling axis. Also, verified it by using Normal View tool, as all the faces were visible, went ahead with B-surface creation.
9. Published the tooling axis & Class-A surface.

10. Then, Draft Analysis can be performed using the obtained Tooling Axis.

Draft Analysis:
Important step to perform prior to Draft analysis is to make sure that the View Mode is set to Material; then proceed.

Performed the following steps during Class A Surface analysis & Closed Surface Analysis:

1. After clicking draft analysis tool, use the compass to define new current draft direction.
2. Pick the red dot and drag the compass near the component. Then hold the dot and place it on the Tooling Axis. And click on the Lock symbol in Draft Analysis tool.
3. And select the component to be analysed. As per the colour code, the Component colour would change to indicate that the Draft values are within certain defined range/ band.
4. Generally, draft analysis is passed when the colour is Green for the selected component.

Result of Draft Analysis:

Class A Surface: After analysis the surface turned green in all direction denoting the draft is more than 2.9 degree.

Closed Surface: After analysis with draft angle as 2.9 degrees, one surface was shown in red i.e. draft was angle 2.22. Hence, step 9 was revised with change in angle to 4.5 degree. Then the draft analysis was green. i.e. draft of all surfaces was more than 2.9 degrees.