Week 9 - Challenge 2 - Switch Bezel Design

PROCEDURE FOR CREATING THE SWITCH BEZEL

• First, the given styling is checked for any irregularities and if found any then it is corrected by using Trim, Extrapolate, split and Join commands
• The below image shows the class A surface is clean and no irregularities present, so let's move on to the next step.

CREATING A TOOLING DIRECTION

• Considering the Ejection from the cavity of the mould after manfacturing the interior trim must have the nominal 3-degree draft ange.
• 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 centre is created and an axis system was inserted to the point with the current feature is 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 centre point is used to extrude a line along the z-direction and gave a measurement of 5 degrees (Tentatively).
• With these two lines from sketches 1 and 2, the bisecting line is crated and published as Tooling Axis(tooling direction).

CREATING 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.
• Finally, the required corners have been filleted and the class B surface is formed

CREATING CLASS C SURFACE

• The required outer edges of the A-Surface were extracted using Multiple Extract. Then for avoiding the patches the curve is smoothened using the Curve Smooth option.
• Then by using the sweep command the surface was created with the following feature controls,

1. Profile type – Line
2. Subtype – With Draft Direction
3. Guide Curve – Smooth Curve
4. Draft Direction – Tooling Axis
5. Draft Computation Mode – Square
6. Angle – 3 Degree
7. Angle Sector – Positive Downward (1)
8. Length – 10mm

• Then by using extrapolate command the edges were intersected between the surface corners which eases the trimming operation.
• Now the required portion of the C – surface were 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.

PROCEDURE FOR DRAFT ANALYSIS

• First the class – A surface is checked before creating the Class –B&C surface and finally the solid body must be analysed. Both can be done by following the below procedures.
• By changing the view mode to custom view parameters – Material mode then the feature draft analysis is enabled.
• Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked 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 colour 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.

PUBLICATION

• Publication is done to the component to make it visible and navigate easily.
• To publish the component go to tools >publicationn and then select the tooling axis and the class A surface.
• A separate tree structure is formed under the main part.

TREE STRUCTURE

CONCLUSION

Finally the class - A surfaces with the Tooling Direction have been Published and the switch Bezel is moved on to the designing of the next operation - the creation of B side feat