PROJECT 14 - CAATIA V5 - SWITCH BEZAL DESIGN ( TRIMS)

Week 8 - Challenge 2 - Switch Bezel Design

Create the Switch Bezel Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. 

Take the Thickness of the component to be 2.5 mm

NOTE:

Tree Structure Ensure Proper Tree Structure

Geometrical sets should have a proper name based on the sketches present inside of it

All the sketches should be created under the Geometrical set

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

Publications: Use the publication option and publish the below

Tooling Axis Class A, B, and C surface

Report –

Aim :

 To create the Switch Bezel plastic component through the given class A surface and create the required Tooling axis and perform the Draft analysis on the model.

Objective :

First create the required correct Tooling axis and perform the Draft analysis on the given class A surface. Create the class-B surface and class-C surface by using the surface modeling tools. And make the closed surface of class-A, class-B and Class-C as the single solid body. And perform the Draft analysis on the solid model.

Theory :

Tooling Axis:

Class-A surface is first analyzed to create the tooling axis or tooling direction that molds pull apart in injection molding. Tooling direction is important for plastic product design as i decides direction for mold separation.

Steps followed for creation of tooling axis :

Reference point is first created on extracted surface.

New axis system is deployed to plot clearance lines.

The X-direction and Y-direction along the class-A were used to create tooling axis.

Two clearing lines were bisected to form tooling axis.

Graphic properties of tooling axis were change before publishing.

Draft Analysis :

The Draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees. A functional part for injection molding has to have drafts facing both cavity and core sides to reduce the risk of damage to the parts an ensure ejection. And also important is to overcome the vaccume forces by letting air in between the metal and the plastic for the part to release properly. Adding maintaining a decent cosmetic finish.

Draft should be a part of design for manufacturing and plastic product Designer should be aware of its need at the outset of the design process. This allows considerations for design requirement to be taken into account.

Nominal values for Draft angle :

3 Degrees is the nominal Draft angle.

7 Degrees for textured surface. At the minimum of 0.5 Degrees can be manufactured by special tools.

But it will increase the manufacturing cost.

Tooling axis creation :

First step is observe the given class-A surface deeply and we can say the larger flat area which is perpendicular to the Tooling axis. So, by considering this thing for this class-A surface tooling direction is near to the Z-axis. so we create the point on the flat surface as shown in figure

Next step is to create the reference axis from X-axis and Y-axis. so for that we take the two side flat surface as the reference and create lines along the faces in the Y-direction by using the intersecting line and by using the bisect line tool the reference axis from Y[1]direction is created as shown in figure.

Next step is to create the reference axis from x-axis too. similarly from the X-direction reference is also got as shown in figure So now we got both direction reference lines so next is to create the main tooling axis. for that we create the surfece along the both reference lines as shown in figure And by using the intersection definition we got the main tooling axis as shown in figure.

Steps followed for Draft Analysis:

1. The part created has to be changed to material mode in display frame.
2. Compass is enabled and align it along with the tooling direction.
3. Lock command is then applied to fix compass along with tooling axis.
4. Color codes are classified and Draft angle is applied.
5. Running point analysis is used to display permissible draft angle.

Draft analysis for CLASS A surface:

Class-A surface :

 The class-A surface is the outermost surface of the plastic component which is also looks fine surface and it is the aesthetic surface that the designer creates as an input part for the design work.

Class B surface -

Class B is the offset of 2.5mm from the class A surface, but the fillets on the class A surface may lead to cause an error while we directly offset the class A surface. To overcome those errors I extracted the bezel rest surface, walls and base of the surface. Now, untrim those extracted surfaces and extrapolate to intersect planes with each other to get the same shape as a class-A surface by trimming those.  now, I offset the trim to 2.5mm on the negative (below) side of the class A surface, after offsetting the trim give the fillets to the edges with the consideration of the thickness.

3

Bezel rest surface offset:  

Final Trimmed and Filleted Class B surface:

CLASS C SURFACE:

The class C surface is the combination of Class A and Class B surfaces. To create the class C surface, I extracted the boundary of the class A surface by using the multiple extract command. Now extended the class A surface boundary by using sweep command with 3 deg of draft angle. After I joined class A with an extended surface and then I trimmed that joined surface with class B surface to get a closed body.

Class B surface:

Final Trim of Class A, Class B and Class C surfaces (to get closed body):

PART BODY:

After creating a closed body, we need to create a solid body from that closed surface. Now go to the part workbench to make the sloid body with the help of the closed surface command.

DRAFT ANALYSIS:

The draft analysis is done after the creation of the solid body by using the featured draft analysis command. Click on the compass symbol and align the compass to the tooling the surface is green color the draft angle is greater than 2.9deg (the green color limit is 2.9 deg), if the surface is red the draft angle is less than 0deg.

Tree structure and command –

Sequence wise – Publication, Axis system, A surface, B surface, C surface, final join surface, solid body, tooling analysis.