Week 12 Challenge

Procedure followed to create the Plastic Knob mold blocks:

• Decide tooling direction and check for draft analysis
• Scale the model considering 0.6% shrinkage i.e. 1.006
• Close the open surfaces using shut off surfaces, keep the bottom open surfaces as no-fill. Use loft surfaces for closing no-fill portion and then knit them
• Create a tooling plane and create the split lines
• Create the parting surface using ruled surface command and knit them together
• Use move/copy body command to create copies
• Knit the parting surfaces with core/cavity surfaces
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• Align the sprue at its location
• Create the inner/outer core blocks using boss extrude. Then use split command to seperate inner/outer block
• Offset the core/cavity surfaces and use cut with surface to form the respective blocks
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• Provide relifs on faces with direct contact using move face command
• We will have to create inserts for the inner features since the depth is more than 50mm and the cutting tool for this length is not available
• Select the top plane and click on the insert's profile than use convert entities to form the sketch. Then use split command to form inserts
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• Use hole wizard command to form holes for bolts for fixing inserts also create holes in inserts using extrude cut
• To form the sliders add a plane at 60mm from top surface and sketch the profile such that the undercuts get covered and then use split command to seperate slider profile from cavity block
• Use boss extrude to add material and use extrude cut to form the wedge for slider. Insert into new part
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• Use combine command to form the slider profile in blocks
• Make necessary edits in the core & cavity blocks to ensure proper fit and easy movement of slider
• Provide relif between core/cavity block faces which are in direct contact
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• To create the ejector pins sketch 6mm circles and extrude them.Provide proper relif and holes in core block also create pin head
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• Select pin head surface and sketch rectangles to form ejector plates. Also, provide pin head relif on plates
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• Now in cavity block sketch circle and extrude cut to form sprue. Use extrude cut,draft,extrude boss,fillet,combine commands to create the runner and gate system
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• Create air vents in the core block use extrude,fillet,mirror & combine commands
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• Now to make the cooling channel across the core block use hole wizard command and specify M10 socket head cap screw type and create multiple cooling channels
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