Week 9 - Challenge 2 - Switch Bezel Design

Switch Bezel Design

AIM: To Create the Switch Bezel Plastic component through the given Class-A surface and perform draft analysis for component.

Introduction

Tooling Axis

• The Tooling Axis is to show in what direction does the core and cavity moves.
• It also created to give a draft angle for the final solid part.

Draft Analysis

• The draft analysis is done on the basis of the Tooling Axis in order to find whether the final product is done as per the Design rules.
• The Draft angle which is assigned to the Tooling Axis defines the analysis.
• The Nominal Draft angle for the plastic product is 3 degree.

Class A

• Class A is the aesthetic surface.
• Class A is created on the basis of a concept sketch or by the predefined shape on basis of the design engineer and customer requirement.
• Class A is given to the Product design engineer in order to get the final solid part.

Class B

• Class B is the surface that is created by the product design engineer in order to get the final product from the class A surface.
• Class B is created based on the thickness that the final solid part should be.
• In other words, Class B is an Extended version of Class A with some thickness gap between them.

Class C

• Class C is the surface that is designed by the product design Engineer.
• Class C is created inbewteen Class A and Class B in order to connect them.

Procedure

Creation of Tooling Axis

• Tooling axis is create by using bisecting method.
• In this, a reference lines are created and with the help of bisecting line and point.
• The axis is created by extrecting the hole and creating a point at the center of hole.
• A plane is create at the cnter point and took a intersection. Drawn two lines with the reference of the intersecton and creted an axis by using bisecting line.

Steps:

A surface is extracted first from the given Class A Surface. A point is created at the center of the surface and a axis system is created at the same point.

A intersection of Class A surface is taken agains YZ Plane and ZX plane.

Two lines are extracted from the intersection taken against YZ plane.

As tooling axis is to b created with the help of bisection method, a bisecting line is created using the extracted line at the center point.

A positioned sketch is drawn in ZX plane. A line is projected from the intersection taken at ZX plane. After that a line is drawn from the center point at an angle of 6 degree to the projected line.

Now, a bisecting line is created with the help of that two lines. And the output line is our tooling axis.

Draft Analysis of Class A Surface:

To perform draft analysis on Class A surfce, change the view mode to material mode.

Select Draft analysis option from the analysis tools. Coincide the compass on the tooling axis created and click on lock direction.

color code for the draft angle i.e green for above 2.9 degrees, Blue for 0-3 degrees, and red for angle value lesser than 0

Draft Analysis of Final Plastic Component:

Creation of Class B Surface:

To create the Class B surface, faces are extracted and untrimmed from Class A seperately.

All the untrimmed faces are extrapolated with curvature continuity.

As the thickenss of component is 2.5 mm, All the extrapolated faces are offsetted by 2.5 mm and trimmed the faces together.

And the B surface is ready

Final Class B Surface with all fillets

Tree Structure for Class B Surface:

Creation of Class C Surface:

To create C surface, Boundary is taken from class A surface.

Using the boundary as guiding curve and tooling axis as draft direction,swept the surafce. This is done using Draft with direction option.

Class C surface is created.

Tree Structure for Class C Surface:

Final Operations:

After creating Class B and Class C Surface, Class C surface is joined with Class A surface.

And this output is trimmed with the Class B Surface.

Final Output:

Creation of Solid Body:

Solid Body is created using Close Surface option available in Part design workbench.

closed surface tool is used to convert the plastic design model to solid form.

Draft Analysis of Final Plastic Component:

After the creation of solid model, draft analysis is performed on the final model.

Conclusion:

1.Class B and Class C is made out of the given Class A using PART and Surface design workbench.

2.Created Tooling axis with the help of bisection method

3.Performed Draft analysis on given Class A Surface and Final Solid model.