Challenge

Week 8 - Challenge 5 - Core & Cavity Design

Automotive Plastic Design using CATIA V5

AIM: To Create the Core and cavity blocks for the switch bezel designed in the earlier challenge.

PROCEDURE:

As the switch bezel is a surface model we have to open it in the GENERATIVE SHAPE DESIGN which is observed in START << SHAPES.
We have to check the Connectivity of the Class A surface which we have uploded.
Ensure that there are no gaps between the surfaces on the class a surface.
Create a point on the class A surface.
Create a axis system on the class A surface by using the point.
Now we have to create a tooling axis for the Class a surface. for that we have first create a new geometrical set named tooling axis.
After creating the Geometrical set, we have to use create a sketch and intersect the model and draw two lines and bisect them to get the Tooling axis.
Finally we get the tooling axis.

Publish the Class A surface and the Tooling axis.
Now we have to create the Class B surface.By using then class A surface we have to create the b surface by using commands like extract,un trim, and extrapolate
Finally, apply the fillets to the B surface by measuring the fillets on the class A surface. and the class B surface is obtained.

Now we have all the 3 surfaces ."I had some problem in boundaries so I expoliated the class A surfaces and fixed the problem"

Now we have to do the draft analysis on the model but before that set the viewing mood to material mood.
Now, go to draft analysis,click in the compass option in direction and bring it to the tooling axis and lock the compass.
Give the draft angle mim and max).
Finally the draft analysis is performed on the model.

After the draft analysis is done in the body we have to create the core and cavity for that we nned to first create a parting surface
First create a new geometrical set and take the class A surface and class C surface and join them together.After that trim the new surface with the class B surface.
Finally we will have the parting surface with the component Area.

If we want the actually parting surface. Joined ClassA and Class C surface and then intersect them both and split them with the curve which we got by intersecting.

Using this parting surface we have ti now create the core for the model.
First, create a new geometry for core design and than insert a sketch with respect to the point and axis which we have created for tooling axis.
Draw a rectangal as shown in the Image and constrain it.

After the sketch is drawn we have to use the extrude option or tool to and extrude the surface according to the tooling axis direction ( this is very important).
Now, trim the ectruded surface with the parting surface which we have created before. then close the surface with fill option and join all the surface and make it a close solid body using close surface in part design.
Finally we will have our core .

After the core is created we have to now create Cavity.For that us ethe same sketch which we have created eariler and extrude it along the tooling axis direction.
After that trim the obtained surface with the class B surface and close the surface with fill tool and make a closed surface with join option.
After thet use the close surface option in the part design and make is a solid body
Finally the Cavity is created.

Now we have to create the parting line.
To create the Parting line we have to first create joint between the ClassA surface and C surface ,then intersectt the joint with the B surface and we will get the curve and that is our Parting line.