Project 2

STEP-1:-

UNDERSTANDING THE MODEL & DECIDE THE TOOLING DIRECTION.

THEN SELECT DRAFT ANALYSIS OPTION

HERE SELECT TOOLING DIRECTION & GIVE DRAFT ANGLE AS 0.5°.

• CAVITY SIDE SHOWN AS GREEN SURFACE
• CORE SIDE SHOWN AS RED SURFACE

SINCE THE GIVEN MODEL HAVE LESSER DRAFT ANGLE, COMMUNICATE TO PRODUCT DESIGN TEAM.

STEP-2:-

SCALE THE MODEL FOR 1.006% (SINCE IT IS A ABS MATEIAL SHRINKAGE VALUE IS 0.006%)

STEP-3:-

THE MODEL IS HAVING SO MANY UNDERCUTS ON SIDES, SO WE HAVE TO SELECT PARTING LINE INORDER REDUCE NO. OF SLIDERS.

STEP-4:-

NOW SELECT SHUT-OFF SURFACE OPTION TO CLOSE HOLE GAPS.

USE NO FILL OPTION IF REQUIRED.

STEP-5:-

THEN CREATE PARTING SURFACE ACCORDING TO PARTING LINE.

USE RULED SURFACE & LOFT SURFACE COMMAND.

STEP-6:-

THEN MERGE ALL PARTING SURFACE BY USING KNIT SURFACE COMMAND.

STEP-7:-

COPY THE KNIT SURFACE CREATED NOW.

FOR THAT SELECT MOVE/COPY BODIES.

STEP-8:-

NOW HIDE THE SOLID BODY & CORE BODY.

SO THAT WE CAN MERGE PARTING SURFACE & CAVITY SURFACE. (DO VICE VERSA FOR CORE SURFACE).

MAKE SURE MERGE ENTITIES & GAP CONTROL CHECK BOXES ARE FILLED.

STEP-9:-

NOW CREATE NEW ASSEMBLY.

AND ALSO CREATE TWO NEW PARTS INSIDE THE ASSEMBLY FOR CORE & CAVITY BLOCK.

SAVE PARTS FILES SEPERATELY.

STEP-10:-

MAKE SURE THAT THE ORIGIN OF ASSEMBLY IS AT RUNNER START POINT. (MAKE SOME MOVES TO PLACE THE ORIGIN AT RUNNER START POINT).

STEP-11:-

NOW OPEN THE CORE PART INSIDE ASSEMBLY.

MAKE SKETCH & EXTRUDE TO CREATE CORE BLOCK.

STEP-12:-

NOW CREATE ANOTHER SKETCH ON TOP PLANE & MAKE SPLIT , TO AVOID 3D PROFILE ON ALL AREA.

STEP-13:-

NOW HIDE THE OUTER BODY & USE SURFACE OFFSET COMMAND TO CREATE PARTING SURFACE INSIDE CORE PART.

STEP-14:-

NOW WITH THE HELP OF CUT WITH SURFACE COMMAND, CREATE CORE BLOCK.

STEP-15:-

USE MOVE FACE COMMAND TO GET STANDARD SIZE FOR CORE BLOCK.

STEP-16:-

REPEAT THE SAME STEPS TO CREATE CAVITY BLOCK.

STEP-17:-

SINCE MODEL HAVE UNDERCUTS WE NEED TO CREATE SLIDERS.

USE SPLIT COMMAND TO CREATE SLIDERS.

STEP-18:-

NOW REDUCE THE SIZE OF SLIDER & MAKE SOME EXTRUDE TO MAKE REQUIRED PROFILE OF THE SLIDERS.

STEP-19:-

NOW SAVE THE SLIDER ALONE AS A SEPERATE PART & MAKE COPY OF SLIDER BODY

USE COMBINE COMMAND TO MAKE PROFILE OF SLIDER IN CAVITY BLOCK.

STEP-20:-

USE DELETE BODY COMMAND TO DELETE THE SLIDER BODY.

STEP-21:-

NOW CLOSE THE GAP CREATED BY EXTRUDE COMMAND.

STEP-22:-

IN ORDER TO GUIDE THE SLIDERS IN CORE BLOCK, CREATE SOME BLOCKS.

STEP-23:-

SINCE SOME SOLID BODY ADDE IN CORE BLOCK , WE HAVE TO CUT SAME PROFILE IN CAVITY BLOCK.

STEP-24:-

GIVE SOME FILLETS ON THE PROFILE OF SLIDER PROFILE.

STEP-25:-

GIVE THE SAME FILLETS IN SLIDER BODY TOO. AND SAVE IT AS XT FILE.

STEP-26:-

SINCE WE HAVE UNDERCUTS ON ALL 4 SIDES OF THE BODY, 4 SLIDERS NEEDED.

SO IMPORT THE RECENTLY SAVED XT FILE.

USE CIRCULAR PATTERN TO HAVE 4 SLIDERS.

STEP-27:-

USE COMBINE COMMAND TO MAKE PROFILE ON CAVITY BLOCK.

STEP-28:-

REPEAT THE SAME STEPS ON CORE & CAVITY BLOCKS.

STEP-29:-

NOW ADD BOLT & WASHERS. MAKE SOME CUTS IN CORE & CAVITY BLOCKS TO ACCOMADATE BOLTS & WASHERS.

STEP-30:-

NOW CREATE INSERTS FOR MANUFACTURING FEASABILITY. USE SPLIT COMMAND.

STEP-31:-

CREATE EJECTOR SYSTEM, IT CONSISTS OF EJECTOR PINS & PLATES.

STANDARD EJECTOR PIN IS OF ø6mm.

NOW MAKE SOME EXTRUDE CUT FOR THE PROVISION OF EJECTOR PIN.

STEP-32:-

NOW CREATE EJECTOR PINS. USE EXTRUDE.

STEP-33:-

PROVIDE RELIEF FOR EJECTOR PINS.

STEP-34:-

NOW CREATE EJECTOR PIN HEAD.

STEP-35:-

NEXT CREATE EJECTOR PLATE.

STEP-36:-

THEN CREATEHOLES ON THE EJECTOR TO ACCOMADATE EJECTOR PINS & PROVIDE RELIEF FOR THE SAME.

STEP-37:-

THEN CREATE EJECTOR BACK PLATE.

STEP-38:-

NOW CREATE RUNNER & GATE SYSTEM.

START WITH CAVITY BLOCK.

MAKE SOME EXTRUDE CUT FOR ALIGNMENT OF SPRUE.

STEP-39:-

CREATE SPRUE. (IT IS OF STANDARD DIMENSION).

STEP-40:-

NOW JUMP TO CORE BLOCK.

MAKE SOME CUT TO ALLOW THE PLASTIC TO FLOW IN CORE BLOCK.

STEP-41:-

MAKE EXTRUDE TO MAKE RUNNERS. USE DRAFTS & FILLETS TO FORM THE PROFILE.

STEP-42:-

NOW DRAW THE ENTRY POINT ACCORDING TO REQUIRED AREA WHICH WILL BE GIVEN BY MOULD FLOW TEAM.

STEP-43:-

NOW USE COMBINE COMMAND TO MAKE THAT PROFILE ON CORE BLOCK.

STEP-44:-

NOW CREATE AIR VENTS. MAKE TWO SMALLER CUTTERS IN CORE BLOCKS , SO THAT ONLY AIR CAN FLOW.

STEP-45:-

NOW CREATE COOLING SYSTEM. THREE THINGS TO CONSIDER HERE IS :

1) DIAMETER OF HOLE

2) DISTANCE BETWEEN TWO CONSCUTIVE HOLES

3) DIAMETER OF SOCKET HEAD.