Week 9 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL WORKBENCH

Objectives: To create SWITCH BEZEL COMPONENT model using the Class-A Surface. It’s a plastic component so by keeping in mind all engineering constraints the model will be designed. This starts with the TOOLING AXIS for the Class-A surface should be created.

Introduction:

Class-A Surface: It is an outermost surface which is developed by the designers and it is provided as an input to the modeller to work on it.

Class-B Surface: It is a surface at a certain thickness from the Class-A Surface.

Class-C Surface: It is a surface that joins the Class-A and Class-B Surfaces.

Commands or tools were used to create a closed surface/solid model, performing on the Class-A surface:

INTERSECT >> EXTRACT >> UN-TRIM >> EXTRAPOLATE >> TRIM >> OFFSET >> EDGE FILLET >> BOUNDARY >> SWEEP >> JOIN >> CLOSED SURFACE (Part Design) >> DRAFT ANALYSIS

Orientation Views:- Front, side, top and isometric views.

FOR TOOLING AXIS CREATION:

• First with the extract command base surface is created from Class-A after that creating a point using point command with the reference of base surface.
• Now creating a dummy tooling line along YZ plane with the position sketch by sketching two inclined lines and then bisecting those two lines.
• Now again with the same process creating second dummy tooling line along XZ plane.
• Finally creating TOOLING AXIS line with the line command using bisecting.

FOR CLASS-B SURFACE CREATION:

UPPER ARM REST SURFACES CREATION:

• First with the extract command the arm rest surface will be created from the Class-A surface.
• After extraction, Un-trim command is used to remove the sharp or curved edges and creating straight edges.
• As the thickness of the component is 2.5mm, so by using offset command the achieved desired shape is now Offset up to 2.5mm distance.

POCKET SURFACE CREATION:

• First with the extract command the pocket inclined surface will be created.
• Now Un-trim the surface to get the straight edge surface.
• Now extrapolate the surface.
• After extrapolation, trim the surface.
• Now offset it by 2.5mm distance.

POCKET BASE SURFACE CREATION:

• First with the extract command the base surface will be created.
• Now Un-trim the surface to get the straight edge surface.
• Now extrapolate the surface.
• Now offset it by 2.5mm distance.

FINAL CLASS-B SURFACE CREATION:

• Now trimming the Upper Arm Rest Surface with the Pocket Surface and then trim the Pocket Base Surface with the achieved surface.
• Finally by providing fillets on the achieved trimmed surface Class-B Surface is created.

FOR CLASS-C SURFACE CREATION:

• First by using the boundary command creating the outer lines, the boundary of the class-A surface.
• Now creating Class-C surface with the sweep command using ‘With Draft Direction’.
• The surface achieved has so many small patches, by using smooth curve command removing the patches.
• It can be seen that at the end edges there is a gap, so to remove it first extrapolate the edges and then trim it.
• Finally Class-C Surface is achieved.

FINAL SWITCH BEZEL SURFACE CREATION:

• Now with join command, join the Class-A and Class-C surfaces.
• After joining of Class-A & Class-C surfaces trim the achieved surface with the Class-B surface.
• Finally the closed surface body of the component is achieved in the surface design.
• Now move to part design with the close surface command, solidifying the component.

FOR DRAFT ANALYSIS CREATION:

• First set material mode, now click on the draft analysis.
• After opening an interface of draft analysis, click on the symbol of datum/compass align it with the tooling axis.
• Click on the surface and see that the surface is within the permissible limit of the draft values.
• Be ensuring that the surface should be green and if not flip the direction of the datum/compass it will turn into green.
• And after flipping the direction still not the draft analysis is not working, close the command and delete the 'Free From Analysis' and perform the process, it will start working.
• And if found that some area is still not turning into green, check the geometrical set or set the tooling axis with different values.

Gomertry and Surface Operations:-