Project 2

There are the steps which is followed by me to create a mold blocks and sliders for the given geometry:-

1. Draft analysis: - For the given geometry first we have to check the draft on the vertical walls so the mold blocks can easily separate from the part. For draft analysis from mold design go through draft analysis command and select the tooling direction the minimum draft required is 0.5⁰ and which wall have minimum draft angle is in green or red colour and which wall not have minimum draft angle is in yellow colour. If there is no draft angle then as a mold design engineer we have to in for the part design engineer to provide proper draft.
2. Scale: - For mold block design we have to give some scale to geometry to create core and cavity surfaces. For that we have to go through given formula of scale (scale = (material shrinkage of geometry/100) + 1) and assume the material of geometry as ABS (given in challenge report) which have shrinkage of 0.6.
3. Parting line: - For parting line we have to choose the edge where the core and cavity surface can easily separate. Sometimes the software can select the right edge but in some case we want to select the edge. In this geometry I selected a top most edge for parting line where both core and cavity surfaces a intersecting.
4. Shut-off Surface: - we have to closed the open loops where the material is not required in geometry. So there we can use shut-off surface command to close that loops.
5. Parting Surface: - For parting surface we have to create a surface along with parting line and with use of move copy body command from direct editing just create a copy of parting surface so we can combine one surface with core surface and another one is with cavity surface.
6. Core & Cavity surfaces: - With Knit surface command we can combine the core surface and parting surface also cavity and copy of parting surface at same plane. So we can separate the core and cavity block with the help of these surfaces.
7. Now open the part file in new assembly file. Create core and cavity part folder in assembly. Now match the origin of assembly and sprue gate location at same point. Also create sliders and washers part file in assembly and save all the files as new part file.
8. Now first we have to locate a origin of assembly at the sprue gate of the model. And then create a sketch with center rectangle where two rectangle is created one to cover entire 3D body of geometry and another one is for 2D body for extra features like sliders and washers. Now with extrude features create a block which cover entire 3D body. With move copy command from direct editing create a same block for the cavity block at same plane.
9. Now with cut with surface command cut the blocks using core and cavity surfaces. Give them colour for core block colour is red and for cavity block colour is green.
10. Sliders: - First with split command split the slider body from the cavity block. Now there are some obstruction in horizontal direction on which the slider is moving. That we don’t want is the slider profile so we have to remove it from the slider and make them another insert profile. Now give the proper size and wedge (wedge angle 30⁰) to the slider so it can easily move with cavity block. Also remove the material from core block which overlap with slider and from the slider path. Also given a fillet which is required for slider and also on cavity block on respective edges. Save the slider body as new body in parasolid file extension so it is easy to insert the file in slider part file. And also remove slider body from the cavity part file with the help of delete body command from direct editing.
11. Create a washers for sliders so it can properly joint with core block and move freely on his path. The dimensions of the washers are standard. Give them a proper place to fix. And remove the material from core and cavity block which overlap with washers. Give extra dimension for relief and in core block use hole wizard command for removing the material.
12. Now give a colour to the washers as black and for sliders yellow colour is given. And also some changes is made on slider in last step so to match to cavity block with sliders body i added the part file of sliders and with combine command from direct editing I subtracted the material which is intersect in cavity block.
13. There is no deep under cuts so we don’t require a inserts, ejector pins, ejector plates etc.
14. Sprue: - Sprue is on the cavity block there are the standard dimensions to create the sprue and also the sprue dimensions are provided by the company. The sprue is the inlet for the material for the mold.
15. Runner: - The runner is along with the sprue so the material can easily pass through it till the gate. The runner dimension is given by the company or we can take from the chart. Or it depends on the material of part also.
16. Gate: - The gate is provided in the mold for passing of material from runner to mold.
17. Air Vents: - Air vents are creating is mold because the after the fitting the mold blocks the air is present in the passage is there is no air vents the after part solidified the defects are on the part. Air vents removes the air from the passages of mold blocks.
18. Cooling channels: - For faster solidification of the material the cooling channels are required. The location of the cooling channels is near to the part. We can made cooling channel by using the hole wizard features. The cooling channels are big enough to flow of the coolant.

With following this procedure, I completed the week 14 challenge project 2.