Week 7 Challenge

Week 7 challenge

Design of slider for 2 undercuts

In the previous challenge I have designed the core and cavity of car door bezel in this assignment I have done the slider mechanism for the car door bezel by using the same core cavity block. which created in previous challenge.

CAR DOOR BEZEL SLIDER

Slider- Due to the special requirements of a product, the mold release direction of a particular part may not be consistent with the mold opening direction of the injection molding machine (product undercut), the slider, also known as slide, is a mold mechanism that is developed to solve the issues with the undercut. The basic principle is to turn the vertical movement of mold opening / closing into a horizontal motion. In order to cope with the situation that the undercut is located in the core or cavity, different structural forms are developed.During mold design of car door bezel in the step of draft analysis we can clearly observe an undercut sliders will be used.

Slider direction will be perpendicular to the direction of the pull which will be horizontal these are separable from the core and cavity 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 blocks itself, and the undercut will be the slots slider are designed in a manner that they will be able to close the slot with an extruded shape of the slot.

PARTS OF CAR DOOR BEZEL

• Core
• Cavity
• Slider
• Washer

PROCEDURE STEPS FOR CREATING SLIDER-

Step 1- we will create a plane by selecting the edge as slider direction as first reference and point as second reference. We will create a sketch on the plane using convert entities and convert the profile on the sketch.

Step 2- we will use the split body command and select the sketch and plane as trim tools and select the cut bodies then we will select the split body that we need as the slider body.

Step 4- we will create another sketch on same plane and use convert entities option to convert the profile of the undercut and extruded it up to the face of the body and other side as 2mm.

Step 5-But there was a gap between the slider body and the profile so we will need to fill the gap. So, we need to use the slider profile part sketch use and extruded it up to the surface such that the gap is filled.

Step 5- now we will create a sketch of rectangle and cut extruded the slider body.

Step 6- then we will create as sketch on top face of the slider and boss extruded it up to bottom surface of the slider. We will create a sketch on the efface of the slider then cut extruded the slider body.

Step7- we will use combine tool to subtract the slider body from the core block. below image show the core body after combine operation done. We will see that there are some additional cuts that we don’t need we will fill these cuts. for this we use move face option select the face for offset and offset value is 10mm.

TOOLS USED FOR CREATING SLIDER-

Reference plane – This command is used for creating plane and axis. the reference plane is created perpendicular to the line of undercut region.

Sketch – using this command we create a new sketch on created new plane.

Convert entities- You can create one or more curves in a sketch by projecting an edge, loop, face, curve, or external sketch contour, set of edges, or set of sketch curves onto the sketch plane.

Split- it is available in feature tab use to split the body into two pieces along the sketch based on application.

Cut extruded- used to remove material from a solid body along the sketch in which direction we need based on application.

Boss Extruded- 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 tool tab used to move face of a solid body.

Move/copy bodies- It is available in mold tool used to move copy and rotates solid body or surface bodies.

Combine- it is available in mold tool tab used to add, subtract bodies.

Delete/keep bodies- it is used to delete the unwanted body from the solid body. Or keep it.

The slider is created using split option making the sketch as the profile of the undercut on plane which sketch is made.

These sliders are modified such that washer and locking mechanism will be correctly designed.

The core and cavity block are made according to the shape of the slider after creating all mechanism using combine command.

After that add separate part file in assembly named as washer, create a sketch for the washer and extruded option used to make washer. Due to add of washer there will be an intersection in core and cavity block we should remove the intersection material.

LOCKING MECHANISM- As the slider movement should redistrict, we should create a locking mechanism such that only some distance slider can move for this certain space should be allocated in cavity block that spaced is designed considering the distance for travel of slider.

Cross section view

Mold design view

Front view

Top view

Isometric view

Conclusion- we are successfully creating the core cavity block with slider washer of car door bezel.