Week 9 - Challenge 2 - Switch Bezel Design

SWITCH BEZEL

AIM:

The objective of the project is to design the solid switch bezel and to do the draft analysis for the product by creating the required tooling direction by using line (Bisecting) method.

DESIGN CONSIDERATION:

• Class – A surface should be aesthetically smooth and good.
• Class – B surface should have all the supporting features like ribs.
• Parting Line should coincide with the B surface since flashing couldn’t affect the aesthetic of Class – A.
• Class – C surface should also pass the draft analysis.

CREATION OF TOOLING AXIS:

• Considering the Ejection from the cavity of the mould after manufacturing the interior trim (switch bezel) must have a 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 into the topic with the current feature 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 4.5 degrees (Tentatively).
• With these two lines from sketches 1 and 2, the bisecting line is created 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 to avoid 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,
• Then, using extrapolate command, the edges were intersected between the surface corners, which eases the trimming operation.
• Now the required portion of the C – the surface was 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 (point 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.

Fig1.1 Class B Surface

Fig1.2 Class C Surface

Fig.1.3 Final output

Fig1.4 Closed surface

Fig1.5 Multi-view (Closed surface)

Fig1.5 Draft analysis of Class B surface.

Fig1.6 Draft analysis of Closed surface

CONCLUSION:

Finally, the Class – A, B&C 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 features.