Week 9 - Challenge 2 - Switch Bezel Design

                            SWITCH BEZEL DESIGN

AIM:

         The project aims to create a switch bezel plastic component using the given class-A surface and perform the draft analysis. 

OBJECTIVE:

• Ensure proper tree structure. 
• Geometrical sets should have a proper name based on the sketches present inside them. 
• All the sketches should be created under the geometrical set. 
• Use the close surface feature to make a solid body from the surface.
• To publish the tooling axis, class-A, B and C surface. 

INTRODUCTION:

CLASS A SURFACE: The class-A surface is used in the automotive design industry. It describe the final production surface data for the aesthetic parts. 

CLASS-B SURFACE: The class-B surface is the second surface that has a surtain thickness from a class-A surface. This surface contains engineering aspects of a model. These must be smooth and "error free" as well but not held to the standards that class-A surface are. 

CLASS-C SURFACE: The class-C finish alows more imperfection than class-A or B. Class-C is often specified for interior surface not readily visible,  surfaces that will be covered by another part when assembled or surfaces

. CREATING TOOLING AXIS:

• The ejection from the mould after manufacturing the interior trim must have the nominal 3-degree draft angle. 
• Hence the tooling direction created by considering the above factor And bisecting method is used. 
• The bass surface of the class-A was extracted to create a reference point on the surface using the point, create the line in the Z-direction and an axis system was inserted to the point. 
• Then using projection intersection along the yz plane is created and the two inclined lines were drawn inside the position sketch. 
• Then bisecting lines with the two inclined lines were created. 
• Now the same procedure is done along the zx plane but on zx plane, we only have one surface line so the center point is used to extrude a line alone the Z-direction and gave the measurement of 4 degree from the surface line
• Bisecting the sketche1 and sketch 2 the bisecting line created and published as a tooling axis. 

 DRAFT ANALYSIS ON CLASS-A SURFACE:

• Go to insert>analysis>future draft analysis. 
• Align the tooling axis with the compass. 
• Click on the surface and see that the surface within the permissible limits of the draft value. 
• The surface should be green and in the column nominal value at 3 degree given as input. Hence the draft analysis on the class-A surface is successfully performed. 

CLASS-B SURFACE CREATION:

• Divide the class-A surface into 3 different surfaces as 1.bezel rest surface 2.side walls 3.base.
• The first step is to extract the surfaces untrim and extrapolate the surfaces. 
• Ofset the surfaces here the input is given as 2.5mm.
• Ones all the surfaces are created the required trim operation were performed to form a class-B surface. 
• To perform the fillet operation. Fillet value should be calculated from the class-A surface for every edge in the B surface. 
• The fillet value should be calculated to ensure the component has a uniform thickness. 

CLASS-C SURFACE CREATION:

• The edges of the class-A surfaces are extracted using the multiple extract and then converted into smooth curvature to avoid the patches. 
• Sweep operation is performed, selecting the smooth curves as the guide curve and the tooling axis as the direction and draft angle as 3 degree. 
• Join class-A and class-C surfaces. Make sure that there is no unnecessary boundary present. It there is then increase the merging distance do not more than 0.003mm.
• Then trim the class-C surface with the class-B surface. 

 Go to part workbench by using the close surface feature we created a solid body from the surface.

 

       

FINAL PART DRAFT ANALYSIS;