Week 9 - Challenge 2 - Switch Bezel Design

                                          DESIGN AND DRAFT ANALYSIS OF SWITCH BEZEL 

Aim: This project aims to create a switch bezel plastic component using the given class A surface following the OEM standard. and perform the draft analysis.

Class A-surface

Introduction:

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

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

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

methodlogy:

Insert the class A surface of the switch bezel in CATIA software. 

Determining the tooling axis for the switch bezel 

Creation of class B surface.

Creation of class c surface.

Join the switch bezel's class A, class B, and class c surfaces and ensure all the surfaces are closed surfaces.

Use the Close Surface feature to make a solid body from the surface. 

finally, Perform the Draft analysis on the switch bezel final plastic component. 

create tooling axis;

The base surface of the class-A was extracted to create a reference point on the surface using the point, create a 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 positioned sketch. 

then bisecting lines with the two inclined lines were created.

Bisecting these two lines sketch1 and sketch2 the bisecting line is created and published as a tooling axis.

DRAFT ANALYSIS ON CLASS-A SURFACE:

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

CLASS-B SURFACE CREATION

1-bezel rest surface

 3-walls

2-Base

once all the surfaces are created (i.e, bezel rest surface, walls, and base surface). The required trim operations were performed to form a class-B surface 

To Perform the fillet operation. Fillet value should be calculated from the Class A surfaces for every edge in the B surface.

The fillet value should be calculated to ensure the component has a uniform thickness.

Class-A and Class-B surface

CLASS-C SURFACE CREATION:

The edges of the Class-A surface are extracted using the multiple extracts and then converted into smooth curvature to avoid the patches.

Sweep operation is performed (with draft direction) selecting the smooth curves as the guide curve and tooling axis as the direction and draft angle as 3deg

join class-A and class-C surfaces. Make sure that there is no unnecessary boundary present, if there is then increase the merging distance to not more than 0.003mm. and even after there is some unwanted boundary, extrapolate class-A by a small distance and trim it with class-c instead of joining them.

Then trim the class-C surface with the class-B surface

THE CLASS-C SURFACE 

Go to the part workbench by using the Close Surface feature we created a solid body from the surface

Switch Bezel Final Plastic Component:

DRAFT ANALYSIS OF FINAL PLASTIC COMPONENT:

Following the similar steps performed for draft analysis of class-A surface, we obtained the following result 

TREE STRUCTURE