Week 12 Challenge

EJECTOR PINS - 

We will start by creating a sketch for the pins, we will make diameter 3mm pins . 

We will then use the cut extrude tool and cut the block with the sketch . 

Now we will use the same sketch and create a boss extrude and on one side give distance as 150mm and other side upto the surface . 

Now we will create relief for the pins on the block . we will create a sketch of circle diameter as 3.95mm . then we will extrude vut the block upto a distance such that we will be atleast 10mm away from outer face . 

Now we will create head for the ejector pins , the sketch is as shown below . then we will use the boss extrude tool and extrude it for 3mm we will merge it with core pins , the head is give a cut because of foolproofing . 

We will create a sketch for the ejector plate . we will use the extrude tool and extrude the sketch for 10mm and untick the merge bodies . 

We will now create a head clearance on the ejector plate for the ejector pins . we will create a sketch as shown belown then we will use the cut extrude tool and cut the plate for 3mm . 

Now we will create anothe sketch for clearance of pins on the ejector plate , we wikk create circles of diameter 3.95mm and cut extrude the ejector plate . 

Now we will create a backplate for the ejector plate we will create a sketch with same profile as ejector plate and then extrude it for 15mm . we will untick the merge result . 

Creation of sprue  - 

We will create a sprue cut on the cavity block , so we will create a sketch of diameter 120mm and then cutextrude the cavity block for 12mm . 

Now we will  create a sketch of diameter 5.8 , this diameter as the nozzle diameter is generally 5.8mm . so we will then cut extrude the block and we will give draft as 3.5degree , and depth we will give such the the entire block is cut . 

We will create a cut on the core , we will a sketch on top face of core , the circle diameter will be of the same diameter as the cut on the cavity block , we will cut extrude it for 5mm .

Creation of runner and gate - 

We will create of the runner in the core block ,  we will then extrude this line for 4mm and keep thin feature as 4.75mm and midplane . we will un tick the merge option . 

We will then give a draft of 10 degree to the runner  . 

We will then apply fillets to the runner as shown below . 

We will then make the gate body , we will create a sketch as shown below then we will extrude it for 0.5mm  . 

We will then give draft on th eface of the gate , the angle of draft will be 40 degree 

We will have to delete this additional surface on the gate  , we will use intersection curve and intersect the outer faces of the runner on the sketch then we will cut the gate with this sketch . 

We will give fillets to the gate body . 

We will use the combine tool and add the runner and gate together . 

We will start a sketch on top face of this body then we will convert the profile of the runner gate body on this sketch we will then extrude it and merge it together . 

We will use the combine tool and delete the core body with this runner gate body . 

Below is the cross section view of blocks showing the runner and gate and sprue . 

Creation of air vents - 

We will create a sketch on the flat face of the core we eill then extrude this sketch for some depth and we will untick the merge option . 

We will then use the split body tool and split this body with the faces , we will then select the body we want to eliminate 

We will then use the move face tool and move the base face by 1mm . 

So as we see below , we have given this 1mm such that it can just penetrate the body by 1mm . 

We will give a fillet of 1mm to the edges of this body . 

Now we will have to create a another cut on the core of 0.02mm such that this cut will only allow the air to flow out and avoid the flow of molten plastic material . so we will start a sketch as shown belown then we will extrude it for a depth such that it passes the core . 

We will then split this body , the split tool will be the same face as we used earlier and we will select the bottom bodies to eliminate . 

We will then move the face by 0.02mm . 

So we will have to now provide cooling channel to this air vent , we will start a sketch as shown below then extrude this for a depth such that it passeds in the core block . 

We will use the split body and split this channel and then we will select the part we want to eliminate . 

WE will use the move face and move it by 1mm . and then we will add fillet of 1mm to the edges . 

We will use the combine tool and add the airvents along with the cooling channel . 

We will then mirror this combined body on the other side . 

Then we will use the combine tool and subtract these two bodies from the core body . 

Creation of cooling channels - 

We will use the hole feature and create a inlet and oulet channel as shown below , similarly we will also create some other channels . 

Below is the  rough representation showing flow of water through the inlet and outlet . we will then share this information to the moldflow team and if the mold flow team validates it correct then we can use this flow or else we will need to modify this cooling channel . 

Exploded view and working of blocks - 

The mold blocks will remain closed till the cooling of the part is finished .

Then the bottom assembly that is the core block along with slider and ejector system will move downwards - 

Then the slider will move outward . 

Then the ejection system will eject the part outside the core block .