Challenge

Week 8 - Challenge 5 - Core & Cavity Design

GGowreddy Chaitanya Reddy3 Jan 2022

AIM: To create the core and cavity for the switch bezel considering all design rules.

TOOLING AXIS:

IT IS THE AXIS IN WHICH THE DIRECTION CORE AND CAVITY OPEN. THIS IS THE VERY IMPORTANT FOR THE PRODUCTION OF PLASTIC COMPONENTS. MOST OF THE DEFECTS WILL BE DONE IMPROPER TOOLING AXIS CREATION BY THE PLASTI DESIGNER.

THERE ARE SO MANY METHODS FOR THE CREATION OF THE TOOLING AXIS. INTERSECT IS ONE OF THE METHODS FOR CREATING THE TOOLING AXIS.

BISECT METHOD:

FOR DOING THIS YOU SHOULD FIND OUT THE WHAT IS THE BEST TOOLING DIRECTION. FOR DOING THAT TO ROTATE THE PART AND SEE ALL DIRECTIONS AND CHOOSE THE WHICH DIRECTION WILL BE COMFORTABLE.

THEN CREATE THE POINT ON THE BASE MOSTLY CREATING THE POINT WHERE THE HOLE OR POCKETS ARE GIVEN. AND AFTER THAT INSERT THE TOOLING AXIS IN THAT POINT. THEN FIRST SEE IN X DIRECTION IT ILL CLEAR THE ALL FACES OF PARTS IF NOT CREATE A PLANE AND INTERSECT TO EACH OTHER. THE FOLLOWING WINDOW WILL APPEAR.

THE CREATE THE MEAN LINE. AND GO TO Y DIRECTION AND DO THE SAME PROCESS WE ARE DONE IN X DIRECTION.

THEN BISECT THESE ALL LINES TO GET THE MAIN TOOLING AXIS. THIS TOOLING AXIS CAN BE CLEARED ALL FACES OF THE PART.

DRAFT ANALYSIS:

THE PURPOSE OF DRFT ANALYSIS IS TO DETECT THE PART THAT SHOULD BE EASILY WITHDRAWL FROM THE CORE AND CAVITY BY USING OF DIFFERENT COLOUR RANGES.

THIS ANALYSIS WILL BE DONE BY DRAFT ANALYSIS COMMAND. FOR THIS COMMAND GO TO INSERT< ANALYSIS< FEATURE DRAFT ANALYSIS

THESE ARE THE FOLLOWING STEPS TO DO THE DRAFT ANALYSIS ON THE SWITCH BEZEL. FIRST TO CLICK THE DRAFT ANALYSIS COMMAND THE FOLLOWING WINDOW WILL APPEAR.

AND THEN CHANGE INTO MATERIAL MODE

THEN CLICK THE COMPASS AND DRAG ON THE TOOLING AXIS. AND THEN CLICK ON THE PART THEN THE COLOUR WILL CHANGE OF THE PART. AND YOU CAN CHANGE THE VALUE USING THE SCALE OPTION. AND ALSO A RUNNING PINT COMMAND IS USED TO FIND OUT THE ANGLE OF PART FROM THE TOOLING AXIS.SO YOU CAN MODIFY THE TOOLING AXIS BY USING A COMPASS TO GET PROPER RESULTS.

DRAFT ANALYSIS REPORT FOR SOLID BODY

DRAFT ANALYSIS REPORT FOR CLASS A

CORE AND CAVITY design for switch bezel:

first of all, you have full knowledge about what is, cavity, parting surface, parting line, etc.

core and cavity:

a core is the one part of the mold. and it is responsible for half of the molded part. actually core is the projection of the body and the cavity is the depression of the body. these core and cavities combine to form a mold. then the plastic material is injected into this mold to get a plastic part.

parting surface:

injection mold has two major components one is core and another is cavity .during the injection molding process, these two halves are pressed tightly from a sealed hollow to avoid the melt flow leakage and maintain certain holding pressure, the pressed surface is called parting surface, usually parting surface is the biggest projection outline of the part.

parting line:

it is the area in which the parting surface and component meet Or it is a junction between core and cavity

and the parting surface has some set of rules because the product quality mostly depends on the parting surface.

DESIGN PARTING SURFACE SHOULD FOLLOW THE FOLLOWING PRINCIPLES :

Design the injection mold simple as possible . Avoid or reduce side parting as much as possible to reduce the complexity of mold making.
Ease of de-molding as far as possible, for instance, the plastic parts should stay in fixed halve of the injection mold and should be ejected by ejection system avoid, side de-molding action,
Ensure the dimension accuracy of the molded parts, Try to make the parts similar dimension accuracy requirements in the same mold to reduce manufacturing and assembly errors.
Ensure appearance requirement of molded parts, finish or mismatch usually occurs on the parting surface, so the parting surface should not be designed on high-quality requirement surfaces.
Ensure adequate venting. If possible parting surface should be placed at the end of the mold flow. This is going to be the advantage of filling and venting.

core design:

To extrapolate class A surface

trim class A with class c to get an inside portion

Now, trim the B surface with an output of Class A & C that will be parting surface with respect to area. Extrude the sketch overall through the tooling direction are trim it with a parting surface.