Project 2

INPUT - 

   

1 - Tooling direction and draft analysis - 

So we have done draft analysis of the part , the part clears in the vertical tooling direction but there are undercuts in the part at four corners , so we will have to create sliders for this under cuts . 

  

Slider direction and draft analysis - 

We have done draft analysis of the part in slider direction , so as we can observe the particular area clears in the direction but there is two faces which is in yellow color will require draft so we will give this information to the product design team . 

      

 

2 - Scale - 

As we are gonna use ABS material we will apply the shrinkage factor of abs to this part which 0.6percent . 

 

3 - parting line - 

So for this part the parting line is simple , we will use the parting line tool and get the parting line for the part . 

 

4 - Shutoff surface - 

We will use the shutoff surface tool and create surface for the open holes in the part . for the complex holes we will keep the option as no fill and we will create surface manually over there . 

So we will use surface loft tool and create surface manually . 

We will use the surface fill tool and create surface for the remaining profile . 

  

 

5 - Parting surface - 

We will create a sketch and use plane surface to create a parting surface , then we will use the trim tool to trim the parting surface with parting line . 

  

 

6 - Core and cavity surface - 

We will use the surface knit tool and knit the all the surface that form the core surface , similarly we will knity for the cavity surface as well . 

   

Below is the cavity surface in green and core surface in red . 

   

 

7 - Core and cavity blocks - 

We will use the tooling split tool and give the necessary inputs like the core surface ,  cavity surface and parting surface . we will get the blocks . we will save these core and cavity bodies as a separate part file . 

Below is the core and cavity blocks - 

    

 

8 - Creation of sliders - 

Below is the cross section view of the blocks ,  so as we can observe there are undercuts produced in the core side due to which the part will not be able to eject , so we will make sliders . 

So in the below image we can see a rough representation of slider is shown . this slider will enable the part to be ejected properly . 

We will use the split body tool and create splits for the sliders . 

    

We will increase the size of the block by offsetting the faces by 70mm . 

 

We will create a sketch for the slider , the profile is as shown below then we will cut extrude the block . 

   

We will create another sketch as shown below and then we will boss extrude it . similarly we will boss extrude for the other two slider . 

   

We will create another sketch and cut extrude the body , similar operation we will do for the other two slider . 

  

We will create another sketch for the guide ways of the slider , we will extrude it upto the vertex . 

    

 

    

Modification on core block according to slider - 

We will create a sketch as shown below on the core , we will extrude it , this will act as a path for the sliders on the core block . 

   

We will provide a draft of 10degree on the vertical faces where the core and cavity will meet . 

 

Modification on cavity block - 

We will create a sketch on the cavity block and we will extrude it . this will be the path of slider on the cavity block . 

   

We will create another sketch and then extrude it . we will apply draft of 10 degree on the vertical faces whwre the core and cavity will meet . 

   

We will create a sketch and extrude it , this is done to fill the gap in the pathway . we will then insert the slider body into the core block file and we will use the combine tool to delete the slider body from the core . 

   

We will then create sketch for the bolt head clearance on the cavity block , we will cut extrude the part . 

      

 

 

9 - Creation of ejector assembly - 

We will create a sketch for the ejector pins we will use the core tool and give sketch as input we will get the pins . 

   

We will use the same skecth and extrude it for 100mm and we will merge it with ejector pins . 

We will create a sketch for the clearnce hole of the pins , we will then cut extrude the core block  . 

    

We will create a sketch for the head of the pins , we will extrude it for 3mm and merge it with the pins . 

   

Below is the ejectorpins - 

 

 

Ejector plate - 

We will create a skecth as shown below for the ejector plate we will extrude it for 10mm . 

   

We will create a sketch for the ejector pin head clearance on the ejector plate . we will cut extrude it for 3mm . 

     

We will create a sketch for the pin on the ejector plate , we will cut extrude the plate . 

 

Below is the ejector plate - 

 

Ejector back plate - 

We will create ejector back plate , we will use the same sketch as ejector plate and we will extrude it for 15mm . 

Below is the ejector assembly - 

We will create holes for the bolts of the slider . 

 

10 - Creation of spruebush hole   - 

We will create hole of diameter 20mm on cavity block , we will cut extrude the block block for 25mm . 

    

We will use the move face and offset the upper face by 12mm , this is done to increase the height of the block . 

 

We will then create a sketch as shown below and we will cut extrude the block with draft of 1.5degree . 

    

 

Creation of cooling channels - 

we will use the hole tool and create cooling channels in the cavity block . the water will enter through the inlet and exit from the oulet in the cavity block . the flow is as shown below . 

     

We will use the hole tool and create cooling channel in the core block . the flow is shown below . 

   

 

Creation of air- vents - 

We will create a skecth as shown below on the core block . we will then boss extrude it for 1mm and untick the merge result .

   

we will then create anothe sketch as shown below and we will extrude it for 0.02mm and we will unmerge it . 

    

We will create a sketch for the path of the cooling channel to flow out , we will boss extrude it for 1mm and umerge it . 

   

We will then use circular pattern to create copies of the vent bodies on other corners . 

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

We will apply fillets to the airvent cuts  . 

      

 

 

Creation of runner and gaate - 

We will create a sketch for the runner and we will use the sweep it with 1.5mm diameter circle profile . 

   

We will create a sketch and convert entities of the circular profile we will boss extrude it for 1.5mm with draft angle . 

   

We will give a fillet , then we will create a circular pattern of this body , we will keep the pattern as 3 . 

   

We will use the combine tool and subtract the runner body from the core body . 

 

Creation of Top plate - 

We will create a sketch for the top plate and we will extrude it for 22mm , we will unmerge it . 

   

We will create a sketch for the register ring and cut extrude the top plate body . 

   

 

Core back plate - 

We will create the sketch as same profile as core block and we will extrude it for 22mm . we will unmerge it . 

 

 

Guide pillar and guide bushing - 

We will create a sketch of diameter 25mm , we will extrude it for 45mm . 

   

We will create a sketch of diameter 18mm and extrude it for 60mm . 

   

We will create a sketch for the guide pin head and we will extrude it for 6mm . 

    

We will create a sketch for the groove for the oil on the guide pillars . we will cut extrude it for 1mm . 

   

We will give a chamfer at the tip and then we will also add fillets . 

   

We will create pattern of this guide pillars . 

Below is the guide pillar - 

We will create a sketch  and then boss extrude it for 6mm .

 

   

WE will create another sketch and then extrude it . 

    

We will create another sketch and then cut extrude  . 

   

Below is the guide bush - 

Other components of assembly - 

Below is the sprue bush - 

Below is the locating/register ring - 

 Return pin - 

Support_block - 

Bottom plate - 

Top plate - 

Core back plate - 

Core block - 

Cavity block - 

Top assembly - 

Bottom assembly - 

Cross section view  - 

Complete tool - 

Movement of the tool - 

Then the slider will move in their respective slider direction - 

Then the ejection system will eject the componenet out - 

 

Movement of tool in cross section view -

The bottom assembly will move downward 

The slider will move in their respective slider direction - 

The ejection system will move the assembly out -