Week 9 - Challenge 2 - Switch Bezel Design

Creating the close body and performing the draft analysis onto it.

Creation of Tooling Axis:

1. Exract the Base surface.
2. Create a point o the surface.
3. The next step is to create an axis system on the surface with the created point as the origin.
4. Create a new positioned sketch with axis system and Base surface and take the intersection of Class A surface with the point.
5. Draw two lines on two surfaces of the intersection.Then create a bisecting line for these lines and put the rest lines in construction mode leaving only the bisecting line.This is the tooling axis for the Y-direction.
6. Similiarly create a tooling axis for the X-direction (by creating the new sketh,intersecting it,then creating a line at an angle of 3 degree from the top surface .)
7. Now bisect these two lines that we got(tooling axis for y and x direction) with the point on the surface as refernce point.This line is the final tooling axis that we require.
8. Change the colour and the thickness of this tooling axis as you want.

Creation Of B-surface:

1. Insert a new Geometrical set as B-surface creation.
2. Create a new geometrical set namely Arm rest under this geometrical set.Extract the top surface then untrim it.
3. Similiarly create a new gemoetrical inside B-surface name it as Side walls.Extract the side walls without touching the fillets.Then untrim it one by one.
4. Unhide the top surface.Extrapolate these side walls and the top surface(with curvature continuity and propogation type as point continuity )so that they can meet each other.
5. Trim all the three walls.
6. Extract the Base ,untrim it and insert in new geometrical set.Then Extrapolate it.
7. Offest the walls,the arm rest and the base to 3mm (thickness of the component) along proper direction.
8. Trim these surfaces to get the final result.
9. Extract the fillet surface of class A and measure the fillet value .
10. Give this fillet value to the final trims we got(Fillet value- wall thickness i.e 15-3 and 14 -3).This is our Class-B surface

Creating C surface:

1. Insert a new geometrical set as Class-C surface.
2. Extract the boundaries of the top surace and front surface of Class A by using the multi extract command.
3. Use smooth curve to smooth the curve and avoid further errors.
4. Sweep the top curve with draft direction as tooling axis.Give the draft of 3 degree with outside direction.
5. Similiarly sweep the front face with 3 degree draft and outside direction.
6. Extrapolate both the sweeps and trim them.
7. Join the class A and class C with meging distance or trim class A and Class C.
8. Finally trim it Class B surface.
9. Select the boundary .If the boundary does not form theoutput is correct.
10. Create a close body in part workbench.

Performing the Draft anaylsis:

1. Switch to material mode first.
2. Select draft analysis.Click on compass.Move and align the compass onto the tooling axis.Apply the lock symbol.
3. Click on red colour crosson surface.Change the colours as >3 degree in green colour,0-3 degree in blue colour and red is negative.Turn the light option off.
4. Click on analysis under the running point .
5. When we moved this option to diffrent edges we found out that most of the edge have 3 degree draft and appeared to be green and some surfaces have 2.97 to 2.99 degree draft .So they appeared blue in colour.
6. So to clear the error we have changed the value of the draft analysis from 3 degrees to 2.9 degree.
7. Other surfaces appeared to be red and blue whos draft andle were less than 0 and 3 resp.
8. This is how we have performed the draft analysis on the body.