Week 9 - Challenge 2 - Switch Bezel Design

Starting with Class A Surface;Firstly try to find Tooling Axis and creating Tooling Axis
- using two lines and a point created a tooling axis by bisecting of both lines
- I put the tooling axis construction elements on a new Geometrical set under parent INPUT
- Also the Class A surface
- created a parent Geometrical set and named CONSTRUCTIONS.
- under the Constructions created B surface Geometrical set and Extracted the first part which is Bezel Rest Surface which is the top part of class A
- After Extraction Untrimmed the the Surface and Offsetted to 3mm as considered Class A is an Limit also but those construction elements in Geometrical set(BEZEL REST SURFACE) as B Surface
as a parent Geometrical set.
- Then extracted the Walls excluding the fillers;untrimmed the three walls one by one and Extrapolated the Each Wall under Point continuity Propagation mode.
- Trimmed the three Walls eachother and offsetted in 3mm and put every construction elements of Walls in a Geometrical Set.
- Lastly Ectracted Base of the Class A surface and Untrimmed.
- After untrim;Extrapolated under Point continuity Propagation mode and offsetted to 3mm
- every construction elements of the Base put under a Geometrical set(BASE).
- after trimmed the three part each other and added fillets to them.
- fillet radius is 15mm for the two at the bezel area and at the top fillet radius 14mm is substracted with the thickness of the part which is 3mm.
- put every Trims and Fillets under an Geometrical Set (B SURFACE TRIMS) as the B SURFACE Geometrical set as parent.
- I got the complete B Surface.
- For the Class C surface; Created the Geometrical Set (C SURFACE) under Construction as Parent..
- By using the Multiple Extract under Tangent Continuity Propogation mode extracted the boundry of Class A surface.
- Used the Swept Definition tool or sweep tool under draft direction and setted to 3degree angle on reference point is Tooling axis created the C surface on both boundries.
- after that smoothen the both surface 0.001mm deviation on the both boundries.
- After creating the C surface noticed Gap between them troubleshooted it with Extrapolating the four edges and trimming.
- For the final process created a Geometrical set (FINAL JOINS).
- After joining the class A and C using the Join tool merging distance of max 0.003mm noticed the small edges is showing while checking using Boundry tool.
- For troubleshooting the problem Extrapolated the Class A Surface egde at 0.009mm in point continuity and trimmed (trim18) with Class C surface.
- For the final part Trimmed with the Class B Surface and trim18 and created the final part.
- For closing the product moved to part design and defined the part body and used the Close Surface tool and selected the (trim19) final surface.
- For the Draft Analysis selected the tool and switched to Customise view Parameters to material.
- On the Draft Analysis Dialogue Box uses the Compass and place it on the Tooling Axis after that lock the draft diection.
- put the Draft analysis box 2.9 degree as green and one surface is showing the lessthan 3 degree and blue colour. for making the manufacturable i checked the tooling axis sketch and
increased the angle of the dummy line from the 3degree to 6 which makes the product to get proper tooling axis and after the problrm solved the product get more 3 degree as manufacturable.
- for making easier I have done the Publication for tooling Axis,CLASS A,B & C Surfaces.