Week 8 - Challenge 5 - Core & Cavity Design

AIM: To create the Core and cavity blocks for the switch bezel plastic component.

REPORT:

• For the given Switch Bezel catpart first we need to make the basic checks i.e. check the continuity of the part ensure that there is no gap between the surfaces we can take the help of surface command for this
• To obtain the Tooling Axis we will have to create tooling clearance axis in X and Y direction and bisect them
• To create the tooling axis clearing Y direction create a axis system and form a intersect of Switch Bezel Class A Surface with respect to the YZ plane
• Now create a point to point line on the faces that might create error and create a bisecting line between the two faces and we would get the tooling axis clearing Y direction
• For the tooling axis clearing X direction form a intersect of Switch Bezel Class A Surface with respect to the ZX plane and sketch a line at 6 degrees from centre and we would get the tooling axis clearing Z direction
• Now create a bisecting line using the tooling line clearing X & Y direction and we would get the Tooling Axis
• For the draft analysis go to Insert-Analysis-Feature Draft Analysis and make sure the view mode is on material
• Inline the compass with the Tooling Axis and lock then click on the Switch Bezel Class A Surface we will get the draft analysis for the Switch Bezel Class A Surface the minimum draft required is of 3 degrees
• When we click on the Switch Bezel Class A Surface it will turn green that means the required draft angle is maintained
• We can change the value of draft angle from the colour scale table and the Class A Surface will change the colour accordingly
• We can also analyse the draft at a particular point on the Class A Surface by moving the mouse cursor on the surfaces
• To generate the Class B surface extract the Class A Surface faces individually untrim them and offset at a distance of 2.5mm
• And finally trim the unnecessary faces and provide fillets we would get the Class B Surface
• To obtain the Class C Surface create boundary for Class A Surface and sweep it with 3 degree draft
• To obtain the final solid Switch Bezel plastic component trim the needless surfaces and join the rest. Then use closesurface command to form solid component
• At the end perform the draft analysis on the solid plastic component
• Also publish the Tooling Axis and Class A,B & C surfaces

CORE & CAVITY DESIGN:

• To design the core and cavity block first we need to make the parting surface
• To create the parting surface generate a boundary from class A surface and extrapol it then trim it with the class C surface then again trim it with class B surface and we wold get the Parting Surface
• To form the core block sketch a rectangle and extrude it then trim the other half and fill it to form a closed surface
• Join the surfaces together and create a solid block by using the closesurface command and we would get the Core Block
• Follow the same procedure to form the Cavity Block
• Create the intersect of core block,cavity block,solid component and parting surface with respect to the ZX plane to get 2D view ot the mold
• Form the intersect of class A & C surface with respect to the class B surface and we would get the Parting Line
• At the end publish the parting surface and parting line

CONCLUSION:

From this assignment I have understood the concepts of mold design and the parameters such as parting line, parting surface, core & cavity block, draft, etc

Screenshots of the Draft analysis report for both the switch bezel plastic component:

Screenshots of the core and cavity blocks in various orientations (Isometric, Front, Side, and Top View):