Week 9 Challenge

Switch Bezel

Aim:

To create the Switch Bezel Plastic component through the given Class-A surface

Steps:

Given Class A:

 

Creating a Tooling axis along Z:

Considering the Ejection from the cavity of the mold after manufacturing the interior trim (switch bezel) must have a nominal 3-degree draft angle.

Hence the tooling direction is created by considering the above factor and bisecting method is used.

The base surface of the class – A was extracted and a point at the center is created and an axis system was inserted into the topic with the current feature disabled.

Then, using project intersection along YZ plane is created and the two inclined lines were drawn inside the positioned sketch.

Then bisecting lines with the two inclined lines were drawn.

Now the same procedure is done along the XZ plane but on one side we don’t have inclined lines so the center point is used to extrude a line along the Z-direction and gave a measurement of 7 degrees (Tentatively).

With these two lines from sketches 1 and 2, the bisecting line is created and published as Tooling Axis (tooling direction).

 

CREATION OF CLASS B SURFACE

For creating the class-B surface the required surface except the offset surface have been extracted and then untrimmed all the surface.

Then all the surfaces have been extrapolated to get intersections between them.

Since the thickness of the Switch bezel is 2.5mm the B-Surface was offset to 2.5 mm and the required trim operations must be carried out.

To get the radius of fillets the filleted surface is extracted and untrimmed the surface and then the radius is measured.

Finally, the required corners have been filleted accordingly.

 

CREATION OF CLASS C SURFACE

The required outer edges of the A-Surface were extracted using Multiple Extract. Then to avoid the patches the curve is smoothened using the Curve Smooth option.

Then by using the sweep command the surface was created.

Then, using extrapolate command, the edges were intersected between the surface corners, which eases the trimming operation.

Now the required portion of the C – the surface was trimmed out.

CREATION OF CLOSED SURFACE

Now the class – A and Class- C surfaces were joined together by removing the gaps in between them with the help of extrapolation (tangent continuity) and Trim surface.

Then the exact surface of the Switch bezel was trimmed from the above-resulted trim surface with the class-B surface.

Then, by defining the part body by using the Closed Surface command in Part Design, the component's solid body is created.

 

DRAFT ANALYSIS

First the class-A – Surface is checked before creating the Class –B&C surface and finally the solid body must be analyzed. Both can be done by following the below procedures.

Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locking it.

Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle.

The green color area shows that it satisfies the 3-degree draft angle. If not satisfied then by using the Running point tool the area is measured and then altered to get a successful draft for the created tooling direction.

 

Bisecting method

Bisecting method is used to find the proper tooling axis using the dummy tooling axis. In Bisecting method, the bisecting line is used which either bisects the two lines or it will show an error which means the two lines are parallel to each other. To know whether the surface is tolerable or not, we intersect the surface with the respective plane and get a sketch that consists of two lines with the help of bisecting line option we bisect the line which creates a line at the midpoint of the two lines.

Screenshots

 

Draft analysis of plastic component

 

Draft analysis of Class A surface