Week 8 - Challenge 5 - Core & Cavity Design

AIM:- To create Core and cavity block of a switch bezel component.

To create a plastic part there are two major components core and cavity. The core has the impression and the cavity have the depression.

Design rules:-

• The proper draft should be given to the part so that the part can be ejected from the core and cavity.
• Minimum 3 degree draft should be given to the Class C surface. If the part has 0 degree draft then there will be friction occurs in the core and cavity.
• The side core should be avoided because the manufacturing cost of the component increases.
• The parting line is the line that split the mold into two halves the core and the cavity. So the parting line should be always in the Class B surface so that we can not see the parting line.
• Avoid sharp corners as the cost to manufacture the sharp corner is very high.
• The thickness of the part should always have uniform thickness throughout the part.

PROCEDURE:-

Tooling Axis:-

The tooling axis is the direction in which the core and cavity open or close. The design engineer analyzes the class A surface and finds the best possible tooling direction for manufacturing the part. Bellow image shows the tooling axis of the switch bezel.

Core:-

• Core design starts with extrapolating the class A surface.

• Then Extrude the rectangle.

• The next step is to trim the extrapolate with the class c surface.

• Then trim the surface with the class B surface.

• Then trim the surface with the extrapolate.

• Finally, fill and join the surface to create the core.

• Billow image shows the close surface of the core.

Cavity:-

• Do the same extrapolate the class A surface and extrude the rectangle.

• Then trim the extrapolate with Class B surface.

• Finally, fill and join the surface to create the cavity.

• Billow image shows the close surface of the cavity.

Parting line and parting surface:-

DRAFT ANALYSIS:-

• To start the draft analysis first go to material view mode customization and select material.

• Go to "Insert>Analysis>Draft analysis"

• Fix the compass in the tooling axis by dragging the compass to the tooling axis.

• Select a show or hide the color scale option under the display.

Various orientation(Isometric, Top, Front, Side view)

• Isometric view

• Top view

• Front view

• Side View

The core and cavity design of the switch bezel is made and the draft analysis of the switch bezel is also performed.