Week 7 Challenge

Procedure followed to create sliders for undercut

• Identify undercuts when checking the feasibility of model for Injection molding, select orientation of part and decide on core and cavity by considering minimum number of undercuts.
• Undercut present in cavity block, hence open cavity block part file from assembly.

Slider profile

• To create slider make a new plane in direction perpendicular to slider motion, make use of face and edge of undercut for defining the plane direction
• Borrow profile of feature using convert entities tool to get profile of slider on new plane. modify the slider size use delete constrains to remove relationship with existing sketch
• To split block into two parts use split command, select sketch and sketch plane to split into slider. Selected region will be slider and rest will remain as cavity block
• Modify slider to add extra material required for making the undercut section, use extrude command.Ensure the extruded material is merged with slider body and not with the cavity block
• Due to draft in the part, slider body is not completely aligned with the feature, use extrude upto surface command to extrude the slider to fill the gap and ensure the same is merged with slider body
• Use extrude cut feature to remove unwanted faces from the cavity block

Sldier main body

• Select top surface of slider profile for creating main body. Create rectangle with edge at distance 40mm from start of slider. Use extrude cut command to remove excess length of slider.
• Create rectangle symmetric with center of slider block on top face of slider with one edge intersecting extreme end of slider. Use smart dimesion to set distance of 15mm from center of the block to top and bottom edges of rectangle. Adjust the distance from start of slider block and start of rectangle to 15mm. Extrude the rectangular face till bottom of block, ensure merge bodies option is checked.
• Select side face of slider to create sketch for making a wedge shape on slider. Length of wedge should be 2/3rd of overall length and angle 30°. Cut the extra material with extrude cut command.
• To modify cavity block according to new profile of slider, we need to remove material from slider block.Create copy of slider body so we can subtract the copied body from cavity block, Use move/copy command. Hide orignal slider body. Use subtract command to remove excess material.
• Create sketch on top face of cavity block and use extrude command to fill gaps in cavity block, use move face command to close gaps in cavity.

Creating different part file for slider body & adding to assembly file

• right click on slider body from feature manager tree, select insert into new part.
• Select format to save file in required format eg- parasolid or step and press save
• Delete slider body from cavity block file
• Open assembly file, update all parts.
• Select insert new part, rename file as slider_01 as we have 2 slider for this part
• Right click on slider_01, click on edit part, click on insert go to features and select imported option.
• from popup window select previously saved model of slider click open to import file to assembly.
• After importing slider model to assembly file, a seperate part file of model will be created in location same as assembly file

Core block modification as per slider block

• Open core block in seperate part file, import slider body to core block by clicking on insert-->Features-->imported.
• Use combine command to remove extra material from core block.Select core block as main body and slider as body to subtract
• To create path for slider, create a sketch and use cut extrude command. Select face of core block and create a rectangle covering entire area to be removed, use constraints to align edges of part.
• After creating rectangular sketch use cut extrude command to cut path for slider from core block.

Adding Guide-rails for slider - To create constrained path for sliders motion

• Since sliders are moving on core block, select and open core block. To create guide rails material should be added to core block.
• Select top face of core block and create sketch on both sides of sliders. Create rectangle sketch, size should be enough to accomodate washers(approx 12mm).
• Extrude rectangle on both sides,bottom side until core block & on top side until bottom edge of slider wedge.
• Check the extruded material is merged with core body.
• since we have added material to core block, to get proper fitment we need to remove material from cavity block.
• Select cavity block and create a rectangular sketch with edges aligned to guide rails
• use extrude cut command to remove material upto vertex of core block guide rail, use through all selection for other direction

Modifying sliders to create platform for bolts and washers

• open slider file, create sketch on top face of slider.
• create rectangle sketch on either side of slider. Keep 5mm inside the slider body on either side and use extrude cut command to remove material. Select upto surface option while extruding and use guide rail top surface as reference.
• since material is removed from slider profile, we need to adjust the profile in cavity block. Open cavity block and use offset surface command in direct editing to move cavity face as per new slider profile
• To make the slider block cavity manufacturable we provide fillets to slider profile. Use fillet option to provide fillets to cavity block and provide same fillets to slider
• match corner radius of slider by providing same fillet to core block

Creating bolts and washers

• create new part file, rename to washers & save as external part file.
• create sketch on top plane
• draw Ø16mm dia circle with distance 5mm from slider. Use linear pattern and mirror entities to create duplicates of washer
• open washer file separately, use extrude command to give thickness to washer & assign separate color to washer
• For creating bolt, sketch concentric circle on top face of washer, use extrude command with merge options turned off to create top of bolt. Repeat same procedure to create bottom portion of bolt
• to create patterns of bolt, use sketch driven pattern. sketch reference points on center of each washer.
• goto linear pattern-->sketch driven pattern , select bolt body to create the pattern
• If required adjust the washer position in assembly, it should be resting on slider block guide rails

Modifying core and cavity block to acomodate washers and bolts

• Create sketch on cavity block on the face where washer starts. Draw circle with diameter slightly larger than washer OD.
• Use linear pattern and mirror entities command to create sketch for all washers
• Use extrude cut with length more than thickness of washer and bolt head combined. Use through all command to cut in opposite direction
• To create tapped hole in core block use hole wizard option
• select appropriate hole specification and use center point of washer/bolt for hole position.Click ok to from tapped hole

Creating locking mechanism for sliders

• To restrict motion of slider locking is required. Hide cavity block and washers & bolts as only slider and core block modification is required for creating locking mechanism
• Increase size of guide rails if requried by using move face command from direct editing and do same changes to cavity block
• Create skectch on top face of guide rail and draw cut profile(without sharp corners) for locking mechanism, use extrude cut command to remove material with slider bottom face selected as reference face.
• mirror same cut on opposite side of guide rail, create plane at center between two guide rails as reference plane
• To modify slider create a sketch on slider top face by considering slider travel distance ie minimum distance slider should travel so that there is no interference between slider and ejected part.
• create circle with distance equal to travel distance from center of slot and use cut extrude to remove material.
• mirror same cut on opposite side of slider,create plane at center of the slider as reference plane