Week 7 Challenge
Mold design and sliders creation for Door Bezel using Solidworks.
In this report mold design and creation of sliders for car door bezel was done by creating each individual part in Assembly workbench following step by step process to attain best result.
As there was the necessity of the slider for the model we should create washer and locking mechanism for the slider.
Assuming the material for the model as ABS (shrinkage-0.6) the scale value is determined as(0.6/100)+=1.006 for the model.
Model: The steps followed and command used for the car and cavity blocks creation are
MOLD TOOLS:
Mold Pull Direction:The direction in which the core moves apart from the mold,Based on the models and the feature in the model the direction of pull is determined.
Draft Analysis: Analysis draft Angles of faces based on mold pull direction for moment of core and cavity blocks.
Draft Analysis for Slider:Analyse draft angles of faces based on slider direction for moment of slider.
Draft Creation:The minimum draft should be 0.5 degree if there was no draft certain draft will be provided to the component.
Scale:Scales the model by a specified factor based on the material provided(Shrinkage Factor).
Parting Line:Parting line seprate the core and cavity surface.
Core and Cavity Blocks: The core and cavity blocks are created as individual part in assembly by inserting the component as core and cavity surface created for Car door bezel.The sprue location will be adjusted by rotating and giving mates with the planes of Assembly.
1.CORE: The core blocks is created using the core surface created and there will be 2 blocks internal and external block which are created considering the minimum distance between mold and the outer edge and the base of slider theses two blocks are due to a curvature in parting line and combined these two blocks act as a single core block.
2.CAVITY: The cavity block is created using the cavity surface created and there will be 2 blocks internal and external blocks which are created considering the minimum distance between mold and the outer edge and the base of slider these two blocks are due to a curvature in parting line and combinedly these two blocks act as a single cavity block.
During the mold design of car door bezel in the step of draft Analysis we can clearly observe an undercut is present to optimize the undercut slider will be used.
Slider direction will be perpendicular to the direction of the pul which will be horizontal and these are separable from the core and cavity blocks as the slider are movable they should have a base for the movement from the model we can easily provide a base while creating the block itself and as the undercut will be the slot the slider are designed in a manner that they will be able to close the slots with an extruded shape of the slots.
The command and steps involved in the creation of slider are
SLIDER CREATION: The command used for creation of slider are
Refrence Plane: This command is used to create a plane axis.
Sketch: Using this command we can create a new sketch.
Convert Entities: It is a tool available in sketching workbench to project the sketch selection on the plane you are sketching and in this tool another option of intersection curve is there which also used to project sketch.
Split: It is available in feature tab used to split the body in two pieces along the sketch based on application.
Fillets: It is used to make fillets to edges of Solid bodies.
Rectangle: It is an entity used and available in sketching workbench to create a rectangle of different types like corner rectangle,centre rectangle,3 point corner rectangle,3 point centre rectangle and parallelogram based on their application.
Cut Extrude: It is available in feature tab used to remove material from a solid body along the sketch in which direction we need based on application.
Extrude Boss: It is available in feature tab used to add material from a solid body along the sketch in which direction,we need based on application.
Move Face: It is available in mold tools tab used to move faces of a solid body.
Move/Copy Bodies: It is available in mold tools tab used to add,subtract bodies.
Delete/Keep body: It is available in mold tools tab used to keep or delete a solid body or surface body.
The slider are modified such that washer and locking mechanism will be correctly designed.The core and cavity blocks are modified according to the space of the slider after all modification of slider using the combine command.
Washer and blots are designed besides the slider base for this seprate space is assigned on the block which modifying the blocks after slider design.As the slider movement should be restricted we should create a locking mechanism such that up to some distance only the slider can move for this creation space should be allocated in the cavity block that space will be designed.
The final mold design with sliders and locking mechanism created will be