Week 8 - Challenge 5 - Core & Cavity Design

                                                                                DETAILED REPORT OF  SWITCH BEZEL CORE AND CAVITY DESIGN

In the previous models we have seen the model of the part using Class A with tooling axis direction.Here we are going to see about the detailed report of Switch Bezel Core and Cavity Design with Tooling axis creation and Feature of Draft analysis.

CREATION OF TOOLING AXIS DIRECTION

First analyse the given Class A on which axis it clears all the faces of the component.

So, with the analyse of the given Class A part we have 3 sided wall surface in the component. We can take the intersection with the xz and yz plane and using bisecting method we have a mean line between the walls. That line can be assumed as an Tooling Axis direction.

YZ PLANE INTERSECTION

To create an intersection line, first create an axis point in the surface. Extract the base surface and create a point using on surface method with the distance value as 0mm.

Switch to the part design model to create a skecth on the yz plane for the intersection.

Draw a refrence line to the drafted face of both side and create a bisect line to get a mean line for the yz plane.

XZ INTERSECTION LINES

XZ plane is one sided face so we take a positioned sketch to xz plane and create an intersection. Draw a line on one side along to the intersection line , for other we draw an random line from the axis point and give angle 3 degree with the other side face. The line is taken as an XZ axis line.

The angle value can be changed according to the part process to next level of development .

BISECTING METHOD

In the generative shape design section create an bisecting line for the xz and yz line axis to get a main tooling axis point of the part.

After the creation of tooling axis check the line whether its created correctly. Select the axis line and make normal to surface, if all the faces of walls and other parts looks visible the we can proccess to next levl for draft analysis.

DRAFT ANALYSIS ON CLASS A PART

Apply the Feature draft analysis to the Class A to know the exact draft angle of each face.

Now it looks clear that mostly all the faces are cleared with 3 degree draft angle. Except the center wall face all looks good. Now we can try to adjust the angle of 3 degree to check whether the center face also clear with the axis line.

It works with the adjust of the angle changed from 3 degree to 4.8 degree.

This one shows the complete value of angles of the part with respective colour variants.

This image discribes the inverse draft direction side of a component.

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DARFT ANALYSIS ON DESIGN MODEL PART

Nothing much chnages in the designed model part with draft analysis, As we already adjusted the angle in the Class A draft analysis. So the drafted faces shows as 10 degree value.

CORE AND CAVITY DESIGN OF SWITCH BEZEL

Now we are going to see about the creation of core and cavity. To create a core and cavity model there should be a parting surface and parting line to  separate the core and cavity side mould. 

PARTING SURFACE

Extrapolate the Class A model to clarify the faces covered by the core side. So we have to patch up the part model trim with the Class C surface to get a core sided face later trim them with the Class B for the parting surface.

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The created parting surface is a temporary one to look clear about the core side. Parting surface is the one which always placed beyond the part. 

CORE SIDE MOULD

To  create a mould for core draw an rectangle covers the part model on the parting surface and iso constrained them with the dimensions. Extract the rectangle on both side and trim them with the parting surface to create a core mould.

Close the above area by fill surface and jointhem with the extruded box. Then convert the trimed part into closed surface to form a solid.

And intersect the part model,parting surface and core mould to know the difference of the core and parting surface with component.

• The blue color line indicates the parting surface.
• It lies on the class B surface which is the lower line and above line is Class C surface.
• The pink color rectangle is the core part.

SECTION VIEW

CAVITY SIDE PART

To create a Cavity side part same as extrude the rectangle both side trim them with the parting surface to lower side.

Fill the upper open surface with FILL feature and join them to get a complete cavity and covert them to closed surface to a solid part. Add the cavity solid with the core intersection to get a clear section view.

PARTING LINE

The parting line is the junction between the cavity and core close area and intersection with the part model is called as Parting line.

To create a parting line intersect the Class C with Class B to get a intersect line between them which is the parting line of the component.

In the second image it clears shows the difference of core and cavity and parting line was an intersection between those sides.

FINAL PARTING SURFACE

We already disscussed that parting surface is the surface which lies below the component alongside class A .

Our Parting surface waas looked overlapped with the part model.So, we need to split the parting surface with the parting to show clear view of part model and parting surface.

To check whether the created Core and Cavity is correct, check with the section view hide the part model and see the gap between the core and cavity the area where the plastic flows through the mould to form a solid part.

 Also apply translation to the core and cavity model and move little bit from the part model to know the clear shot of core,cavity,part model and parting surface.

PUBLICATION

Use publication tool to higlight the every final surface it helps to search the required surface easily.

DIFFERENTIAL VIEWS OF CORE AND CAVITY

ISOMETRIC VIEW

FRONT VIEW

SIDE VIEW

TOP VIEW

GEOMTRICAL SETS OF CORE AND CAVITY