Project 1

PROJECT 1 -  TABLE FAN OUTER CASING - 

INPUT - 

Below is the outer casing of the table fan we have to create suitable moldblocks for this part . 

 

 

a- Draft analysis -

We will use the draft analysis tool and select the tooling direction and get the draft analysis for 0.5 degree .  so as we can see the yellow mark face requires draft so we will give this information tp pdd team and they will provide us with updated model .  we will use this model for now . 

b- Scale-

We will use the scale tool and scale the part by 1.006 that is 0.6 percent of shrinkage of ABS . 

c- Parting line - 

We will use the parting line tool and create a parting line for the part . 

d - Shut off surface - 

We will create shutoff surfaces for the open holes . as we see the once the shutoff surface is created we get a message that the part is separable into core and cavity . 

 

e - Parting surface  - 

We will create a sketch for the parting surface and then we will use planar surface and create a surface for this sketch . 

 

    

We will use surface trim and trim the planar surface with the parting line . 

f - Core and cavity surface - 

We will use the move/copy tool and create a copy for the parting surface . 

We will use the surface knit tool and knit one copy of parting surface with core surface , we will again use the knit surface tool and knit the cavity surface with other parting surface . 

   

Below is the core and cavity surface - 

 

g - Creation of blocks - 

Cavity block - 

As we are working in assembly mode we will need the cavity surface in the cavity part , we will use the surface offset and offset the cavity surface by 0mm .

We will create a sketch for the block then we will use the extrude toll and extrude the sketch . 

We will use the cut with surface tool and cut the block with the surface . 

Below is the cavity block - 

 

Core block - 

Now similarly we will offset the core surface from part file into the core body . 

We will create a skecth for the core block same as cavity block , then we will extrude this sketch . 

Then we wil use the cut with surface tool and cut the block with the surface . 

Below is the core block - 

h - Creation of sliders - 

Cross section view of the assembly  - 

In the below image we can see that the cavity block could not be separated as there is a undercut present in the part . so for this we will need to create sliders for these two undercuts . 

We will create a plane at the face as shown below . 

We will first create a pin for top hole , so we will  create a sketch of circle on this plane and then we will extrude it upto the face  . then we will create another skecth of the bigger circle and then extruse it for some distance . so this is the pin 1 . 

We will then create another sketch for the pin2 , we will extrude it upto the face  , we will ntick the merge result . 

Now we will create a sketch for the slider body we will use the split body tool and then select the body we need as slider . 

Now we will create a sketch on side face of the slider , the sketch is as shown below then we will cut extrude the slider . 

Then we will use the sketch we used during split and we will extrude it and merge it with the block , the length of extrude will we upto face such that the whole length of the block is filled . 

Now we will create guide ways on the slider , we will create a sketch as shown below and then extrude it upto vertex and merge it with slider body . 

So as our part is symetric we will use the mirror tool to mirror the slider and the pin body onto the other side, as we need another slider also . 

 

We will use the combine tool and combine the pin and slider bodies  . 

   

Then we will save this two slider bodies separately as parasolid files and then we will use the combine tool and then we will subtract the two slider bodies from cavity . 

We will use the move face and offset the faces by 20mm such that the path is created for slider . 

We will then create a cut on cavity for the bolting space , so we will create a sketch and then cut extrude the block upto the selected face .

We will then give a fillet of 4mm on the edges as shown below - 

We will need to make the guideways of the slider on the core block , we will create a sketch as shown below and then we will extrude it upto vertex . 

We will then provide draft to the vertical faces of the core and cavity block such that the rubbing of the two blocks is reduced.

 

    

We will add the inserts as separate file in the assembly , we will provide fillets of 4mm to the sliders . 

Below is the cross section view of assembly  - 

 

Creation of ejectorpins and inserts   - 

 ejectorpin - 

We will create sketch on bottom face we will keep the diameter of circle as 6mm . 

We will use the same sketch and then extrude it 230mm and merge it with the ejector pins . we have created this extra extrude so that the ejector pins will eject the part completely . 

We will create a sketch for clearance hole of diameter 6.95mm for the ejector pins. we will cut extrude the block upto length that atleast 10mm gap is left between this extrude and top surface . 

We will use the move face tool and move the face of block by 20mm this is done to create more path area for the  sliders . 

We will then create a sketch on face of ejector pin , the sketch is for the pin head , we will keep the diameter of head as 10mm .  we will extrude it for 3mm and merge it with the ejector pin bodies . 

Creation of insert - 

We will create a sketch as shown below . 

We will then use the splitbody tool and split the core body with this sketch and the face as marked below . by this we will get 4 insert sin the core block . 

  

We will then create bolt clearance on the core block , we will use the hole tool and create the holes at locations as shown below . 

We will create a sketch for the hole on insert , the diameter of hole will be 5.2mm and then we will cut extrude the inserts for 18mm . 

We will create a sketch for the ejector plate we will extrude it for 10mm . 

We will then create clearance for ejector pins head on the ejector plate, we will keep the clearance head as 12mm and we will cut extrude the plate by 3mm . 

Wewill then create a sketch for the pin clearance on the ejector plate , we will keep this clearance diameter as 6.95mm then we wil cut extrude the ejector plate  . 

We will then create a ejector back plate , we will create a sketch and then extrude it for 15mm and tick the unmerge option . 

Hardwares - 

We will add hardwares to the assembly . 

We will now create holes for the hardwares on the core block, as it is m6 bolts we will create a sketch of diameter 5.2 circle and then cut extrude the block . 

We will thenn edit the cavity block to create bolt head clearannce on it , the size of clearance hole will be diameter 17mm and we will cut it for 9mm . 

 

 Creation of air vents -

We will start a sketch in the core block the sketch will follow the profile of the curve profile of the part . we will then extrude it for 1mm . we will untick the merge result . 

We willgive fillet of 1mm to the edges of the body . 

  

We will create another sketch for the smaller air vent , we will extrude it for 0.02mm . 

We will create another sketch for the airvent , we will extrude this for 1mm . 

We will apply fillet to the edges . 

We will then mirror the airvent bodies onto the other side . 

We will then use the combine tool and subtract the airvent bodies from the man core body . 

Below is the cross section and zoomed-in view showing airvent - 

 

Assembly of blocks - 

Below is the block in the closed position . 

Then the lower assembly that is the core block , sliders , ejector assembly will move downwards along with the cooled part . 

Then the sliders will move outward in their respective slider direction . 

The ejector assembly will eject the part out of the core block .