Week 12 Challenge

1.
Now save the part file in a new assembly file. Create two new part files and save them in the same assembly file. Renamethe two-part files as core and cavity steel blocks.
2.
Check the origin of the assembly. Float the model and mate the corresponding planes according to the gate location as themodel has deep cuts on all the four corners. The part is rotated to 45º using the ROTATE COMPONENT command. Thegate location is not given in the model, so the center portion is selected as the material inlet location. Fix the model.
3.
4.
Edit the core steel block. Take the top plane and sketch a rectangle with a length as 360 mm and width according to theejector plate width (220 mm standards will be given in the industry catalog) + spacer block (2×45 = 90 mm) + slider (50mm) = 360 mm.
5.
Extrude the rectangle using the EXTRUDE command in both directions with 200 mm (try to keep the thickness of themold as low as possible).
6.
Now using the OFFSET SURFACE command, offset the core surface with 0 mm.
7.
Cut the extruded surface using the CUT WITH SURFACES command. The core block is created. Assign a red color to theblock.
8.
As no curved or 3D profile is present at the parting surface, no need to create an inner core block for the present model.
9.
Edit the cavity steel. Select the top plane and use the same rectangle sketch of the core block. Follow the same steps tocreate the cavity block. Assign a green color for the cavity block.

SLIDERS
1.
For the present model, an estimation of four sliders is required in all four corners.
2.
Select the top face of the core block. Sketch the slider such that not thin steel should present either in the slider or theregion of the slider in the core block.
3.
Create a reference plane up to which the slider should present.
4.
Use the SPLIT command with a plane and sketch it in the tooling section. Click on cut bodies. Select the slider region.
5.
On the side face of the slider, CUT EXTRUDE the extra region. For the slider to move while removing the cavity block,sketch the wedge shape on the side of the slider with 30º and heigh as 2/3
from the top surface.
6.
7.
Sketch the bottom portion of the slider to create the slider pathway, sketch a rectangle with 5 mm and extrude to thewedge surface.
8.
9.
Save the slider in the external file in the same assembly path file.
10.
11.
Subtract the slider form the core region using the COMBINE command and subtract option.
12.
Using the MOVE FACE command clear the pathway for the slider in the core region.
13.
Sketch the core region where the pathway is created to accommodate washers for the slider to move.
14.
Create washers in separate part files and in the same region where washers are present, create holes in the core block usingthe HOLE WIZARD tool.
15.
Sketch the locking mechanism in the core region and slider path region. Make sure the move sufficient distance (extra 5mm) for the smooth removal of the part from the mold.
16.
Edit the cavity region. Extrude the region where the slider part is present. Create holes for the washers and nuts.
17.
There is a 90º contact between the cavity and core block. So a relief of 2 mm is provided in the core block at all thecontacts