Week 9 - Challenge 2 - Switch Bezel Design

Aim:-

To create the Switch Bezel plastic component from the given Class-A surface. Also to create the tooling axis by meeting the requirements of the draft angle and perform the Draft analysis on the model.

Fig.1: Switch Bezel.

Tooling Axis:-

The direction with respect to the component in which the mould opens and closes is the tooling axis. Basically it defines the direction in which the mould pulls apart.

Procedure to create the tooling axis:-

For this model, Bisecting Method was used to create its Tooling Axis:

• First, the given Class-A surface was observed carefully from every direction to find in which direction the Tooling Axis can be created.
  
  
  Fig.2: Given Class-A surface.
  
  
• Then, the bottom surface of the Class A surface was extracted and a point was created at the centre of the extracted surface.
  
  
  Fig.3: Point on the extracted surface.
  
  
• Then, an Axis System was created at that point and also a plane was created on the yz-plane passing through that point.
  
  
  Fig.4: Axis System and Plane on the created point.
  
  
• Then, the intersection of the surface was taken along that created plane.
  
  
  Fig.5: Intersection of the surface along the plane.
  
  
• Then, two lines were created along the two lines side surface of the intersection curve and a bisecting line was created using these two lines and passing through the center point.
  
  
  Fig.6: Bisecting line using two lines.
  
  
• Then, another line was created using a sketch on the xz-plane of the axis system at an angle of 6 degrees from the side wall.
  
  
  Fig.7: Sketch on xz-plane.
• At last, using the above two lines again a bisecting line passing through the center point was created.
  
  
  Fig.8: Final Bisecting line.
• Hence, the Tooling Axis was created.
  
  
  Fig.9: Tooling Axis.

Draft Analysis:-

The draft analysis is used to analyze whether our part model created in CAD is manufacturable based on the draft angle and the tooling direction provided. It also enables us to detect if the part will be easily removed from the mould or not. The ejection of the part from the mould depends on the draft angle.

Fig.10: Draft analysis of the given Class-A Surface.

Class-B Surface:-

Class-B Surface was created by extracting the Class-A surfaces and offsetting them by 2.5 mm. Then the surfaces were trimmed with each other and at last edge fillets were applied considering the thickness of the component as 2.5 mm.

Fig.11: Class-B Surface.

Class-C Surface:-

Class-C Surface was created using the boundary of the class-A surface and sweeping it along the tooling direction.

Fig.12: Class-C Surface.

Final Trim:-

The Final Trim of the Switch Bezel was created by joining the Class-A and Class-C surfaces and trimming it with the Class-B Surface. At last, it was converted into the Solid Model by using the Close Surface command.

Fig.13: Joined Class-A, Class-B, and Class-C Surface.

Fig.14: Solid Model.

Fig.15: Back View of the Model.

Fig.16: Side View of the Model.

Fig.17: Top View of the Model.

Fig.18: Tree Structure for the Geometrical Sets and the Part Body of the Model.

Fig.19: Draft analysis of the Solid Model.

Conclusion:-

The Switch Bezel plastic component was created from the given Class-A surface. Also, the Tooling axis was created and perform the Draft analysis was performed on both Class-A Surface and the solid model.