Project 1

The mold design for the given table fan part has been created using assembly in solidworks.

1) First the draft analysis for the mold is done and the parting line for the mold is decided. It has been notted that there are undercuts in the mold. Therefore the draft analysis for the undercuts too are done and altered accordingly.

2) The parting surface has been created and the core and cavity surfaces are seperated from the given part.

3) Now the core and cavity surfaces are uploaded in the assembly section. First the orgin of the assmebly and orgin of the mold are aligned such that the sprue center of the mold is made equal to the orgin of the assembly.

4) Now using the core and the cavity surfaces the core and cavity for the mold are created using cut with surface feature as 2 seperate parts.

5) Now the cavity is checked for features which cannot be machines together. Such feature has been identified and a seperate cavity insert has been designed for easy machinability of the cavity.

6) Now necessary ejector pins are created for ejection of the part using demolding process.

7) The necessary sliders for the undercut has been identified and created such that the sliders does not make a hinderance during demolding of the part.

8) The guide rail for the sliders has been created and a third plate has been included due to the position of the sliders. Finger cams are designed and placed in the third plate such that the slidersmoves a maximum distance of 20mm for ejection of the part

9) The length of the finger cam has been calculated using the given formula. It has been found that 60mm long finger cam at and standard angle of 30 degree will be sufficient for moving the slider for 20mm during demolding process thus helping on ejection of the molded part.

10) Neccesary stoppers for the finger cam has been given

11) The runner diameter for the mold has been calculated using the runner dia formula given. Assuming part weight as 250g and lenght of the runner is 182mm,. Thus the runner dia is 15.68mm.

12) Runner and gate openings and the sprue iand locating rings are designed for the mold.

13) The necessary bolts are provided at placed for fastening the locating ring third plate and top plate firmly.

14) The limit bolts for arresting the movement of the cavity from the third plate is given. Such that the cavity moves 100mm from the third plate.

15) Undercuts near the gate points has been given which helps in breakage of the gate from the part during removal of core from cavity. The detached runner can be removed using hand or robot.

16) The ejection system for the mold is created such that the ejector pins move 120mm from the core surface thus successfully ejecting the part from the core surface, but stoping it from falling down from the mold which may cause some surface damage. Here after ejection the molded part can be removed using hand or a robot for safe removal of the part.

17) The necessary guide pillars, guide bushes, ejection springs are given along with bots which fasten them at their places securely.

18) The support bars are given which help in correct movement of the ejector plate and ejector back plate towards the core back plate and helps in preventing the bending of the plates due to the ejection force exerted by the machine.