Week 9 - Challenge 2 - Switch Bezel Design

PROCEDURE TO CREATING CLASS A SURFACE:-

• First, the given styling surface is checked for any irregularities and if found any then it is corrected by using Trim, Extrapolate, Split and Join commands.
• The Class A surface has some irregularities shown in below figure.So join operation performed on the surface and it became clean surface.

CREATION OF TOOLING AXIS:-

• Considering the Ejection from the cavity of the mould after manufacturing the interior trim (switch bezel) must have the 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 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 6 degrees (Tentatively).
• With these two lines from sketches 1 and 2, the bisecting line is crated 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.

CREATION OF 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 – 20mm

• 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.