Week 9 - Challenge 2 - Switch Bezel Design
DESIGN AND DRAFT ANALYSIS OF SWITCH BEZEL
OBJECTIVE:
The objective of the project is to design the switch bezel and to do draft analysis for it by creating the required tooling direction with the help of bisecting method.
INTRODUCTION
The control panel bezel is the frame part of the window switch that holds its switch covers and button into place. Moulding is the method used to manufacture the plastic trims of an automotive by most OEM's, hence by considering the manufacturing consideration switch bezel is designed.
DESIG CONSIDERSTION
- Class - A surface should be aesthetically smooth and good.
- Class-B surface should have all supporting features like ribs.
- Parting line should coincide with B surface since flashing couldn't affect the aesthetic of Class-A.
- Class-C surface should also pass the draft analysis.
- First, the given stylish surface is checked for any irregularities and if found any then it is corrected by using Trim, Extrapolate, Split and Join commands.
- Considering the Ejection from the cavity of the Mould after manufacturing the interior trim (switch bezel) must have the nominal 3° 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 center is created, and an axis system was inserted with the current feature is disabled.
- Then, using project intersection along YZ plane is created and the two inclined lines were drawn inside the position sketch.
- Then bisecting line with the two inclined lines were drawn.
- Now the same procedure is done along the XY plane but on one side we don't have inclined lines, so the center point is used to extrude a line along Z-direction and gave a measurement of 5°(Tentatively).
- With these two lines from sketch-1 and sktech-2, the bisecting lines is created and published as Tooling Axis.
- For creation of class-B surface the required except the filleted surface is extracted and untrimmed.
- Then all the surfaces have Extrapolated to get the intersection between them.
- Since the thickness of the Sitch Bezel is 2.5mm the B-surface was offset to 2.5mm and the required trim operations must be carried out.
- Finally, the required corners have been filleted to 12.5mm and 11.5mm (Fillet value - Surface Thickness).
- The required outer boundary of the Class-A surface was extracted using Boundary command. Then for avoiding the patches the curve is smoothened using the curve Smooth option.
- Then by using sweep with draft direction command the surface was created.
- Now the class-A and class-C surfaces were joined together by removing the gaps in between them with the help of Extrapolation and Trim surface.
- Then the exact surface of the Switch-Bezel was trimmed from the above resulted trim surface with Class-B surface.
- Then by defining the Part Body by using the Closed Surface command in Part Design workbench, the component's solid body is created.
- By changing the view mode to custom view parameters- Material mode then the feature draft analysis is enabled.
- Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked it.
- Then, by selecting the quick analysis mode, the nominal value will be 3° and checked for the component's draft angle.
- The green color area shows that it satisfies the 3° draft angle. If not satisfies then by using the running point tool the area is measured and then altered to get a successful draft for the created tooling direction.
Finally, the Class-A, B & C surfaces with Tooling Direction have been Published and Switch Bezel is moved on to the design of the next operation-the Creation of B-side features.