Week 9 - Challenge 2 - Switch Bezel Design

DRAFT ANALYSIS ON CLASS A SURFACE -SWITCH BEZEL

DRAFT ANALYSIS ON FINAL CLOSED SURFACE - SWITCH BEZEL

REPORT ON DRAFT ANALYSIS OF CREATION OF CLOSED CLASS A SURFACE -SWITCH BEZEL

1.Visual Inspection -

• The first step of the draft analysis is to determine whether the given class A surface contains any side core functionality that needs to be achieved in the component.
• This can be done by visually checking/insepecting the class A geometry completley step by step.
• Any basic geometrical features such as chamfer,fillets,holes are assumed to be cleared through the direction of tooling axis that are perpendicular to that of the tooling axis.
• Use Join/boundary command to check if all surface edges are closed.Use surface boundaries in Tools-options also to ensure proper enclosure of surface.
• In the given switch bezel class A surface,there is no side core requirement to produce the component with respect to tooling axis.However,the surfaces in the switch bezel pocket needs to be analyzed as they cotain three different geometry.

2.Understanding injection molding process -

• Any geometrical surface that are not aligned to perpendicular direction of the tooling axis needs a separate side core in the mold to create the injection molded component.
• Plastic injection molding process requires core and cavity to form a plastic component.Under injection of high pressure the plastic components is formed.The direction of movement of the core and cavity where it opens and closed is said to be the tooling axis.
• Apply nominal draft of upto 3 deg on both side i.e.. 1 1/2 deg each side to the surface,according to the design rules for plastic injection moulding component this allows for easier ejection and no defects after cooling.

3. Creation of Tooling axis -

• After the proccess of visual inspection,we know that for given Class A surface of switchbezel does not require any side core for plastic component to be produced.The next step involves in deciding the tooling axis selection,this can be x,y or z direction.For switch bezel the tooling axis can taken from z-axis as the geometry of switch bezel is perpendicular to that of tooling axis.

z-axis

y-axis

x-axis

• To check if the three surfaces of the class A can be cleared in the direction of tooling axis, create an axis system on the switch bezel by using point on surface command as reference.

• Create a sketch1 with bisecting line between the two surfaces using project 3D elements. After this change them to construction elements.

• Create another sketch2 on the remaining one wall surface using project 3D elements ,then create another line that is 3deg

• Now,bisecting both sketches which has references of all wall surface will be used to create the Main tooling axis

• After creation of Main tooling axis,perform draft analysis from Insert- Analysis - Feature draft analysis

• Enter 3 deg of color scale variant to control the nominal draft angle under which the surface needs to be formed.This color scale can be changed by double-click (or) to color scale mode from quick analysis to full analysis mode
• Then,use angle running point for identifying angle of the surface.

• Pick the Compass and place it on the created tooling axis by clicking on the red dot and click to drag.

• Use Lock command to hold in place the compass.
• Change direction of the draft only if required .This changes the core and cavity side with respect to tooling axis

• Click ok to perform draft analysis to the given Class A surface.The result of the draft anlysis will be available under Free form analysis - Draft analysis tree structure.