Week 9 - Challenge 2 - Switch Bezel Design

TITLE :- SWITCH BEZEL DESIGN

AIM :- To create the Switch Bezel Plastic component through the given class-A surface and perform the draft analysis on final component and Class A surface.

OBJECTIVES :-

• Creation of tooling axis for given class – A Surface.
• Creation of Class B and Class C surface
• Perform Draft analysis for given class A and final component.

TOOL USED :- CATIA V5

Introduction :- In this project we are designing a switch bezel using given class A surface. The approach includes creation of tooling axis , Class B surface and Class C surface keeping the given thickness 2.5 mm.

CLASS A:- Following surface is given as the input for the component creation:-

To continue design first we need to create a tooling axis for class A surface.

Creation of Tooling Axis :-

• First create a axis system in point 1.
• Create a sketch using intersection command with class A surface and zy plane.

• Check all the portion of sketch and create lines on the sketch portion which will probably does not intersect the tooling line.
• Then create a bisecting line selecting the drawn lines and vertical dummy axis.
• Repeat the process with zx plane and class A surface and create a dummy axis.
• In this case, we don’t have two faces to create a bisecting line so we have to give required angle between face and a drawn line and the resulted line is a dummy axis for zx plane.

Creation of Class B surface :-

• Now for class B creation, extract the class A surface and untrimmed the surfaces.
• Trim the surfaces according to the required class A surface.
• Now offset the surfaces with the given thickness.
• Create fillets for required edges.

Creation of Class C surface :-

• Create boundary of class A surface and use sweep command to create the surface with 3 degree draft angle.

• If the C surfaces are not properly joined then extrapolate them and trim it.

FINAL TRIMS :-

CLASS C SURFACE + CLASS A SURFACE

• Finally trim the joined surface with class B surface to get the final surface body of component.

PART BODY :-

Use the close surface command in part workbench to change the surface body into closed surface to get the final component.

DRAFT ANALYSIS OF CLASS-A SURFACE:-

Different colour shows the different draft angles on the surfaces.

green colour - more than or equal to 3 degree

red colour - 0 to less than 3 degree

blue colour - -ve draft value

Draft ANALYSIS OF FINAL COMPONENT :-

RESULTS ARE SHOWN BELOW-