Week 8 - Challenge 5 - Core & Cavity Design

CREATION OF CORE & CAVITY DESIGN AND DRAFT ANALYSIS FOR SWITCH BEZEL

Objective:

The main objective of this project is to create the core & cavity design and the draft analysis for the Switch Bezel using Catia V5.

Introduction:

The draft analysis will show the important angles of the body, it is very important to maintain positive draft angle. The draft analysis is made on a part to ensure that there is ease in removal of the component from the mold once it is solidified. The core and cavity design are made to get the part manufactured in accurate manner, the core is the projected side and the cavity is the depressed side, the parting surface here is made for the good finishing surface side, it is the side where the parting of an object and core takes place, thus the part after solidification can be ejected easily.

Methodology/approach:

• For the creation of tooling axis and draft analysis, the first important input is the class A surface, then further using Catia V5, create the tooling axis and draft analysis, first, check the best direction (X, Y, Z) and select the direction at which is very easy to manufacture. Z direction is selected for the Tooling axis. For reference if required create the dummy tooling axis in Z direction keeping the point as reference.

• Create a plane in ZY direction on the reference point and then create an intersection curve of ZY plane of the switch bezel. To get the bisecting line of the two line at an angle, create two lines and bisect them to get the tooling axis.

• Create a sketch in ZX plane and draw the line for bisecting line creation. Then draw the bisecting line for both the lines created.

• Publishing – Use the publish option to publish the Class A surface and the tooling axis, so to use them easily at creating some features.

• Thicken the Switch bezel using some of the surface features, since the edge fillet has to be at equal distance on the offset surface, we add the thickness for the edge fillet, the final offset will be the B surface.

• The C surface is the surface which gives the draft angle to the thickened body, using the tooling axis we can obtain the C surface.

• Then join and trim them to obtain the thickened part surface.

• Using part design create a solid body from the closed body feature.

• Then, use the feature draft analysis to check the draft analysis of the Switch bezel using the tooling axis.
• Use the analysis>Feature draft analysis toolbar to check the draft analysis, Use the compass and place in the Z direction line being upwards and lock it.

• Select the axis and the part so that the color changes according keeping the reference as tooling axis.

• On the quick analysis mode there are 3 colors green, red and blue. We can change the values as per our standards, it is good to main standard drafting angle of 3 degrees
• Analysis on running point - with the help of this option, the angles at every point can be checked easily.

The draft analysis is obtained for the closed surface of switch bezel.

• For the core and cavity design, the core is designed in such a way that the projection side is taken into consideration, then by creating a core block.

• The parting surface is the surface which is in between core and cavity, at the component area the parting surface is on the core side but the parting line and parting surface is on the B surface area, this actually avoids come amount of flash and also the class A surface finishing will be good enough.

• The cavity design is taken fully as B surface area with the extruded block, the cavity block will be fixed, after the part is solidified, the cavity will be fixed holding the part and easy for removal.

Different views of the switch bezel with core and cavity design:

• Front view

• Left side view

• Isometric view

• Top view

Conclusion:

The core and cavity design, draft analysis, tooling axis, B surface and C surface are created for the class A surface of the switch bezel.