Week 8 - Challenge 5 - Core & Cavity Design

CORE AND CAVITY DESIGN FOR THE SWITCH BEZEL MODEL

OBJECTIVE:

• To create tooling axis for the switch bezel model.
• To design core and cavity for the switch bezel model.

DESIGNING METHODOLOGY:

CREATION OF TOOLING AXIS

• The first thing to create the tooling axis is to analyse the class A surface through visual inspection.
• When we see the class A surface in isometric view we can clearly see that it consists of basically two types of surfaces one is a nearly flat surface and the other one is forming a kind of pocket into the flat one.
• The flat surface is not going to create any problem during the tooling operation but the second one which is in a shape of a pocket can create problem during tooling.
• So to clear the pocket walls we will first extract and untrim the base surface of the pocket and then insert a point in the middle of the base surface, after that we will insert the axis system on that point.
• In order the to clear the side walls of the pocket we will intersect the YZ plane of the axis system with the class A surface with the help of intersect command. After that we will create lines along the side walls with the help of the obtained intersection curve.
• After drawing these two lines we will create another line which will bisect the earlier drawn two lines, we will use bisecting line option to create this line.
• To clear the front face or wall of the pocket we'll again use intersect command to intersect the ZX plane with class A surface, from here we'll get an intersection curve with the help of which we will create a line along the front wall of the pocket. we will create a line which be at an angle of 6 degrees to the previous line and passing through the point at middle of the base wall.
• Finally we'll create a final line which will bisect both tooling lines clearing X and Y directions and this line will be called as the main tooling line.

PARTING SURFACE CREATION

• Take class A and class C surfaces and join them using join command.
• Trim the resulting join of class A and class C surface with class B surface using trim command.
• The resulting trim will be called as the parting surface.

DESIGNING OF CORE

• Create a position sketch in which draw an rectangle enclosing the class A surface completly with sufficient margin.
• Extrude the sketch along the direction of tooling axis.
• Trim the resulting extrude with class B surface.
• fill the other end of the resulting trim using fill command.
• Finally go to part workbench and use the closed surface command to convert the closed surface into solid body.
• The resulting solid part is the core for the switch bezel.

DESIGNING OF CAVITY

• Take the same sketch that was used in core design and apply extrude command and take the direction of tooling axis as the direction of extrude.
• Trim the class B surface with the resulting extrude.
• Cover the the opened end of the resulting trim using fill command, the resulting entity will be a closed shell of cavity.
• Convert the resulting shell into a solid body by using closed surface command in part workbench.
• The resulting solid body is the cavity for switch bezel.

CORE AND CAVITY DESIGN

TREE STRUCTURE: