Week 8 - Challenge 5 - Core & Cavity Design

Aim :

Create the Core and cavity blocks for the switch bezel designed in the earlier challenge.

Procedure :

1. Parting Surface
2. Core Design
3. Cavity Design
4. Draft Analysis

Procedure for Parting Surface :

• Extract the Class A surface boundary lines with boundary option.
• Extrapolate the Class A surface by 10mm.
• Trim the extrapolate surface with Class C & Class B respectively.

Procedure for Core Design :

• Open new sketch in xy plane.
• Create a rectangle and constraints it.
• Extrude the sketch on both sides.
• Trim the Parting Surface with above surface of the rectangle.
• Fill the open surface with the fill option.
• Join the filled surface with the trimmed surface and create close surface from part workbench.
• Translate the bodies in required directions.

Procedure for Cavity Design :

• Trim the extrude surface with b surface.
• Fill the open surface with the Fill option.
• Join the filled surface with the trimmed surface.
• Now open the Part body.
• Create two bodies separately and create closed surfaces.
• Intersect with the perpendicular plane and unhide the tooling axis.
• Translate the bodies in required directions.

Procedure for Draft Analysis :

• Go to the Insert menu and select the Analysis option.
• Select Feature Draft Analysis.
• Select the Material option and select the surface.
• Drag the compass and place on tooling axis.
• Make sure that the top surface is in green colour as draft angle should not exceed 3deg.
• Click on Okay after confirm the model.

Parting Line:

Parting line is created by intersecting method. Class A & Class C are join together to form parting line.

Yellow dotted line as shown below

Result:

Core Block and Cavity Block:

1. Core

2.Cavity

3.Component

4.Parting Surface

5.Parting line

6.Tooling Axis

Thickness Measure By Intersecting Method:

Pink line- core

Green Line- Cavity

yellow line - flow space

Blue line - parting surface