Week 9 - Challenge 2 - Switch Bezel Design

AIM:

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

:

• CLASS A SURFACE:

                Class A is the surface created by concept sketches done by free hand sketches. The finished sketch is then transferred to a computer, and the 2D surface is created using software such as Alias. This computerized design is known as a Class A surface.

• CLASS B SURFACE:

                Class B is a reference surface created by the design engineer and is a copy of the Class A surface at a distance equal to the part thickness.

• CLASS C SURFACE:

                Class C is again a reference surface created by the design engineer to connect Class A and Class B surfaces, also known as the side walls of the surface.

• GIVEN CLASS A SURFACE:

• The technique used to create the model is to first create a type B surface at a distance equal to the thickness (here 2.
  5 mm) and then a vertical surface of CLASS C.
  Then cut the three surfaces to get the desired part.

• Steps for creating the CLASS B & C SURFACES:

• TOOLING AXIS:

• First we need tooling direction so need to create the tooling axis
• The model is observed from 3 planes and the xy plane is chosen for the details. So the pocket base were chosen and a point has been created 
• Let the point taken has the refernece and create a position sketch and then create the two line in the opposite direction 
• Then create the another line by using the bisecting line option
• An then create another position sketch other two side of the pocket same as well what should do in the previous sketch
• Now create the another line by using bisecting line option and given name has "TOOLING AXIS" 

• DRAFT ANALYSIS:

• Now perform a draft analysis using the draft analysis tool included in the tools. 
• Then, after opening the draft analysis toolbox, find the compass and align it with the axis of the tool, click the lock icon after alignment, and click add to the surface.
• Checking the surface it should lies on 0.5 to 3 deg  and in our case it should lies on the 3 deg

• CLASS B SURFACE: 

• A geometry set withh name bezel switch was created, then the entire CLASS A surface was extracted separately.
• First thing we need do the Bezel rest surface were extracted and do offset through 2.5mm
• Then do same thing for the pocket wall like wise bezel rest surface and Again do same thing for the pocket base 
• Now we got the untrimed Bezel switch like wise mention below

• Now trim the all surface and given fillet as per the CLASS A surface but some different have it offset through 2.5mm from Class A suface so given the accurate values for the each edge fillet i.e 14 - 2.5 = 11.5
• Apply the fillet value then we got the part like this

• CLASS C SURFACE:

• The Boundary were created for the CLASS C SURFACE from the CLASS A SURFACE
• Now using the sweep command and given reference as main tooling axis, then givne direction of the tooling were considered to create clsss C surface
• Then we got the CLASS C SURFACE like this condition:

• FINAL JOIN:

• Now Join the all three surface like CLASS A & C Surface and we got like this

• Then trim with CLASS B SURFACE and we got final output like this

• DRAFT ANALYSIS:

• In Plastic Design, the draft analysis or angle that is considered in the OEMs is 3 degree.
• Same thing were do follow for the draft analysis on earlier and output mention below
• Then we got degree has 2.92 deg

• Draft analysis on the solid part resulted in green, blue regions.
• The green area shows the part that can be machined or manufactured by the casting machine and the angle of inclination is 3 degree
• The blue area indicated that the part may be OK for some OEMs but still needs improvements for other manufactures because the draft angle is greater than 3 degree
• A red color not appearing in this case indicates that the till angle is less than 3 degrees and cannot be manufacuted or if manufacturing will be defective.

• SOLID BODY:

• The hollow is then created as a solid by selecting the Body option and then selecting the Close body surface and hence we got the final output were mention below

• DIFFERENT ORIENTATION WERE MENTION BELOW:

• TREE STRUCTURE:

• FILES:

• The output file were mention on browe option in the name of the "week 9 challenge 1 (Bezel Switch).zip"  and also output image were uploaded in the same folder.