Week 8 - Challenge 5 - Core & Cavity Design

Objective: Creation of the Core and cavity blocks for the switch bezel

Steps:

1. Tooling axis creation

• Extract the base surface, create a point on the surface, insert the axis system on the point created
• Go to sketcher by selecting suitable reference plane. In this case select YZ plane to get tooling direction in Y-axis
• Take the intersection of class A with reference plane
• Draw two lines on the intersection line of class A. Use the bisecting line command to get the bisecting line of these two lines. This line is tooling direction in y-direction

• Similarly get the tooling direction in x-direction

• Bisect these two lines to get the tooling axis

2. Draft analysis

• Go to Insert - Analysis - Feature draft analysis. Before that customize view parameter mode to material.
• Click on compass icon and align it with the tooling axis and click on the surface, we will get our rersults.

From the above image it is seen that surface in green colour has greater than 3 degree draft which is most required for tooling feasibility. Below is the image of draft analysis in various orientations

3. Core and Cavity design

• Extrapolate the class A surface. Also select the extrapolated C surface and B surface.

• Trim the extrapolated class A with extrapolated class C surface.

• Select XY plane - Go to sketch - Draw the rectangle which should include the whole surface

• Extrude the rectangle along tooling axis, then trim the outer edges.

• Make it solid body. This will be the core.

• Similarly develop the cavity block by using B surface

• Complete core and cavity blocks

Below is the image showing Parting line