Week 8 - Challenge 5 - Core & Cavity Design
STEP 1: CONNECTIVITY OF CLASS-A SURFACE
- First check the connectivity of the given surface or component
- This is done by creating boundaries or by using Join command
- Ensure that there is no gap between surface connection
- From this image we can see the boundary inside the surface, it indicates there is a gap.
- To solve this gap, use join option to merging the gap (use merging value as 0.003)
STEP 2: TOOLING AXIS CREATION
- First visually analyse the possible direction of Tooling direction.
- Create dummy tooling axis for possible dolling direction.
- Using the Intersection command create intersection line for all X,Y,Z axis direction.
Inter section of Y direction:
Inter section of X direction:
- If we have a surface with one sided wall, then create a opposite wall with own.
- Make angle contraint for this line with wall.
- Bisecting these X,Y directions tooling axis, the main tooling axis will create, Where the two lines and one point will be selected as inputs
STEP 3: B-SURFACE CREATION
- B-surface creation is done by offsetting class-A surface to required thickness.
- Offsetting class-A surface with fillets are more complicated, so go with extract and untrim the surfaces.
- Extract the all the sketch or surfaces used to create object and Untrim it.
Untrim:
- Extrapolate the surfaces till interact each relative surfaces.
- OFFSET it into required thickness of part
- Trim the surfaces to get proper surface without fillets, then fillet it.
FILLET
STEP 4: CLASS-C CREATION
- Create the boundary around the given Class-A surface.
- If this boundary has more surface, then split it into two or more boundary around the surface.
- Here the boundary has lots of intermidiate joints, this create gap while sweeping.
- To clear this joint make smoothening the curvaure.
- Now sweep the boundary with direction of tooling axis.
- This sweeping area is the thickness of the Class-C surface.
- Make extrapolate the sweep area to attain the intract with Class-A and Class-B surface if required.
- Do trim operation sweep area with both class-A&B surfaces.
After done Trimming operation the finel Class-C surface created.
- For make it solid use close command on Part workbench
STEP 5: DRAFT ANALYSIS
- Draft analysis is done after determine the tooling axis.
- Ensure weather all the surface angles are more than 3 degrees along with tooling axis direction.
- There are some colour codes are used to easily determine the angle value
- If the whole angle is more than 3 degrees, then surface colour turned into Green for one type scale and for another scale it has 5 colour variation.
- Here our surface area has more than 3 degrees.
- Below 0° angle indicated by red in colour, these are has negative angles.
STEP 6: PUBLICATION
- Create publication for Tooling axis, Draft analysis and B&C-surface creation
TOP, FRONT, SIDE & ISOMETRIC VIEW OF AN CLASS-C SURFACE:
CORE AND CAVITY CREATION:
CORE DESIGN:
- Draft analys the given solid part.
- First extrude the class-A surface for create parting surface and trim it with B-surface.
- Draw the sketch (rectangle) around the component.
- Extrude the sketch along with Tooling axis and trim it with the class-B surface.
- close the open surface and make it as solid.
CAVITY DESIGN:
- Take B-surface as a reference for cavity block.
- Draw the sketch (rectangle) around the component.
- Extrude the sketch along with Tooling axis and trim it with the class-B surface.
- close the open surface and make it as solid.
PARTING SURFACE:
- Parting surface is the holding or matting surface of the core and cavity.
- A parting surface is a surface that separates the mold block into two parts – the core and the cavity.
- Here blue line with mold surface called parting surface.
PARTING LINE:
- Parting line is a border line in which draft angle changes the direction.
- Parting line is a junction between core, cavity and component.
- Dotted line with yellow colour called parting line.
- Outer surface of the parting line called parting surface.
VIEWS:
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