Week 7 Challenge

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Week 7 Challenge

MOLD DESIGN & SLIDERS CREATION FOR DOOR BEZEL USING SOLIDWORKS

This report details the mold design and slider creation process for a car door bezel using SolidWorks. Each component was meticulously crafted within the assembly workbench, following a step-by-step methodology to achieve optimal results. To accommodate undercuts, sliders were designed, incorporating washers and a locking mechanism.

The bezel material was specified as ABS, necessitating a scaling factor to account for shrinkage. Using a shrinkage rate of 0.6%, the scale factor was calculated as:

Scale Factor = (0.6/100)+1=1.006

MODEL

The steps followed and commands used for the core 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 features in the model the direction of pull is determined

• Draft Analysis:

Analyse 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 degrees, 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 separates the core and cavity surfaces.

• Shut of Surfaces:

Create mold shut off surfaces, it prevents the flow of injected material by creating shut off surfaces.

• Parting Surface:

Create parting surfaces between core and cavity surfaces.

• Core & Cavity Blocks:

The Core and cavity block are created as individual parts in assembly by inserting the component as Core and cavity surfaces 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 block 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 these two blocks are due to a curvature in parting line and combinedly these two blocks act as single core block.

2. Cavity

The cavity block is created using the cavity 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 these two blocks are due to a curvature in parting line and combinedly these two blocks act as single cavity block

During mold design of car door bezel in the step of draft analysis we can clearly observe an undercut is present, to optimise the undercut sliders will be used.

Slider direction will be perpendicular to the direction of the pull which will be horizontal and these are separable from the core and cavity blocks as the sliders are movable, they should have a base for the movement form the model we can easily provide a base while creating the blocks itself, and as the undercuts will be the slots the sliders are designed in a manner that they will be able to close the slots with an extruded shape of the slots.

The commands and steps involved in the creation of slider are:

SLIDER CREATION:

The commands used for creation of sliders are:

• REFFERENCE 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 selected on the plane you are sketching and in this tool another option of intersection curve is there which is also used to project sketch.

• SPLIT:

It is available in features tab used to split the body in two pieces along the sketch based on applications.

• FILLETS

It is used to make fillets to edges of solid bodies.

• RECTANGLES:

It is also 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 applications.

• CUT EXTRUDE

It is available in features tab used to remove material from a solid body along the sketch in which direction, we need based on applications.

• EXTRUDE BOSS

It is available in features tab used to add material from a solid body along the sketch in which direction, we need based on applications.

• 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 moves, copies and rotate solid and surface bodies.

• COMBINE

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

Washers and bolts are designed beside the slider base for this separate space is assigned on the blocks while 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 certain space should be allocated in the cavity block that space will be designed considering the distance of travel of slider.

In conclusion,

This report successfully outlines the detailed process of designing a mold and creating functional sliders for a car door bezel using SolidWorks. By meticulously applying mold design principles and utilizing SolidWorks' advanced tools, we effectively addressed the challenges posed by undercuts and material shrinkage. The creation of precisely engineered sliders, complete with integrated washers, bolts, and a locking mechanism, ensures the mold's efficient operation and the production of high-quality parts. This project demonstrates a comprehensive understanding of mold design workflows, highlighting the importance of accurate analysis, precise scaling, and the strategic implementation of sliders for complex geometries. The successful integration of these elements ultimately contributes to a robust and effective mold design solution.