Week 8 - Challenge 5 - Core & Cavity Design

                                                       Design and Draft Analysis on Switch Bezel Core Cavity Design

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Tooling Axis:

The tooling axis of the product tells us the direction of movement where the part is being produced effectively.

There are Some advantages if we follow the effective tooling axis like

The side cores and other things can be reduced.

The tooling axis has to be produced by considering some criteria’s like

• Direction of movement
• Bosses and other references have to be considered.

Creating Tooling axis by using CATIA V5:

The above image shows the different directions where the tooling axis possible to produce.

The tooling axis is not restricted to a particular direction. It can be produced in that direction where the product can be produced easily.

Bisecting method:

There are several ways to create a tooling axis, one of the methods is the Bisection method, where the line is created by bisecting the other lines and the point.

In the above picture the tooling axis is created by using bisecting method.

Step1:

The intersection is crated directly in a sketch by using intersection option, were created by simply using intersection tool

Step 2:

The lines are drawn by taking the intersection lines are references. Just make sure to select the two points as a line type.

Step 3:

The two lines were drawn by simply selecting the two points.

Step 4:

The tooling axis is created by using the line tool, just make sure that to select the bisection option as a line type.

Step 5:

Bisecting lines are drawn by simply selecting the lines which are drawn above and the middle point.

Core and Cavity Design:

Core design:

the core is a moving plate of the injection mold. clamping the cavity and core plates together results in the formation of mold. The core plate has several fixed structures like die lockers, which help in locking both cavity and core plates together. Ejector pins are passes through the core plate, which helps to remove the part after gets solidify.

The core design is in this project is done by using simple surface tools like Extrude, Fill, join, and closed surface.

Cavity Design:

the cavity is a fixed plate of the injection mold. clamping the cavity and core plates together results in the formation of mould. The plastic is injected under pressure into the mold through the cavity, cavity plate has a runner and gating system, through which the material flows continuously without any interruption into the mold. not only that cavity plate serves as a supporting structure to the part.

The core design is in this project is done by using simple surface tools like Extrude, Fill, join, and closed surface.

Parting surface:

The parting surface is used to define the core and cavity parts. Where several defects have occurred if the parting surface is not located in the position.

Defects like Flash, Flowlines are affecting the part and external operations are required to remove these defects. Hence the cost of the manufacturing process is increased.

Draft angle: Usually draft angle is provided on the part and the core and cavity to reduce the wear and tear of the product while ejecting from the mold.

Draft analysis is nothing but the analyzing the draft angle provided on the part as well as the core and cavity of the injection mold by the Engineer

The draft angle allows ejector to simple push, to pop out the part from the mold

There are certain standards that should be followed to provide the draft angle on the parts, core and cavity.

• Usually, the nominal draft angle 3deg is provided on the part
• Providing the nominal draft angle is easy and very economical.

Draft angle is depending on the material which is being used to prepare the product.

Ex: Textured parts required more draft angle than the usual

Draft Angle Of 1 To 2 Deg:

There is a thumb rule that the part with a depth of 2 inches requires a draft angle of 1-2 deg for easy removal of the part.

Steps to Analyze the Draft:

Step 1:

To Analyze the draft angle first we need to turn on the draft analysis tool feature.

To turn on the draft analysis tool feature need to follow:

the above picture showed the way to turn the feature draft analysis.

If the draft analysis showed the error like wrong draw mode:

Needs to select the new material type which is there at the bottom with the question mark.

After selecting the new material, a pop-up is shown with several options, in those options needs to turn on the material type, and click ok.

After that, click the same feature draft analysis option which is available in the insert.

Step 2:

Check the draft angle of the faces by clicking the options available on the toolbar.

The popup below the draft analysis tool bar shows the range of the draft angle of the face with the different colors.

The above toolbar conveys that the coin holder's draft angle is above 3 deg so it shows in the green color.

The above tool bar it shows the range of the draft angle of the Class-A surface.

If the Draft angle of the face is above 20 deg it shows the face color in red. If the draft angle is in between the 2-20deg it shows in sky blue color.

From these options, we can analyze the draft angle of the part surface.