Week 9 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL DESIGN

OBJECTIVE : To design the switch bezel by creating a class B and C surfaces using the given class A surface, creating tooling axis and performing draft analysis.

CREATING TOOLING AXIS

• Tooling axis is created using the bisecting method.
• Extracted the base flat surface of class A and created a reference point in the center.
• Inserted an axis system in the reference point with current feature is disabled.
• Intersected the class A along the yz plane and drawn 2 lines along the sloped faces.
• Then created a bisecting line for the 2 lines through the reference point.
• Intersected the class A along the xz plane, but here there was only one suface line.
• So i draw a line through the reference point with a measurement of 5 degree from the surface line.
• Then i bisected this line with the first created bisecting line and created the final tooling axis.
• Published the tooling axis.

DRAFT ANALYSIS ON CLASS A SURFACE

• Changed the view mode to Material mode.
• Insert>Analysis>Feature draft analysis
• Activated the compass and then by dragging the red point, placed the compass along the tooling axis and locked it.
• Clicked on the part and analysed the draft angle of component.
• Considered the min. draft angle as 3 degree.
• The green colour area shows that the component satisfies the given draft angle which was 3 degree.

CREATING CLASS B SURFACE

• Extracted the Bezel rest surface, slopped walls and the flat base surface separately under each geometrical set.
• Then untrimmed and extrapolated each surface.
• Offseted the extrapolated surfaces in proper direction to the thickness of the component.
• Trimmed the offseted surfaces together.
• To measure the correct fillet radius, extracted the filleted face from class A and untrimmed it and then measured the fillet radius.
• To ensure uniform thickness, the thickness of the component is decresed from the measured fillet value of class A surface.
• All the fillets were given.

CREATING CLASS C SURFACE

• Using the multiple extract command, the edges of the class A surface were extracted and then converted into smooth curve to avoid patches.
• Sweep operation "with draft direction" is performed by selecting the smooth curve as guide curve and tooling axis as direction and draft angle as 3 degree.
• Used smooth curve command to remove the patches on C surface.Then replaced the corresponding multiple extract with that smooth curve created.
• Extrapolated the edges to meet the gaps and trimmed.
• Joined class A and C together. Then checked if there were any unnecessary boundary present.
• If there were then, I would have increased the merging distance, not more than 0.003mm.
• And even after if there were any unwanted boundary present then, extrapolate class A by a minimal value (eg:0.05mm) and trim it with class C instead of joining them.
• Then trimmed the join with the class B surface.
• Finally, under the partbody used the close surface to make the component solid.

DRAFT ANALYSIS ON FINAL SOLID COMPONENT

• Final draft analysis is performed just like the steps explained in the draft analysis of class A surface.