Week 8 - Challenge 6 - Core & Cavity Design

NOTE: I have Attached the Report, Photos and CADpart in the Attachment

Week 8 - Challenge 2 - Switch Bezel Design

AIM:

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

OBJECTIVE:

• Tree Structure
• Ensure Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set 
• Use the Close Surface feature to make a solid body from the surface. 
• Publications: Use the publication option and publish the below
• Tooling Axis
• Switch Bezel Solid / Surface body
• Parting Line and Parting Surface
• Report
• A detailed report should be done explaining the draft analysis and the tooling axis creation. 
• An explanation should be given on the way of creating the tooling axis, particularly the Bisecting method. 

SOFTWARE USED : CATIA

Let us look at how we have designed switch bezel and create tooling axis for draft analysis.

INPUT:

CAD DATA is downloaded and Opened with CATIA.

TOOLING AXIS:

Tooling axis is defined as such all the featres of the part can be manufactured easily. so here we followed the below steps to create the tooling axis.

• Extract the bottom base and Create a point in the middle of the surface. 

• Add a axis system on the point and create a sketch such that we get a bisecting line between the two opposite faces.

• Create another sketch of line which is 7 degree apart from the surface.

• The Tooling Axis is attained with bisecting the sketch 1 and sketch 2 line. Add to publication.

DRAFT ANALYSIS:

• Draft is done on the Class A surface. 
• Change it to material in customise view.
• Click the Draft analysis tool and click the surface and align the compass to tooling axis.
• 3 degree is the clearing angle
• So here is photo of cleared (Green) draft.

B SURFACE:

• B surface is created by using the given Class A surface.
• Apart from fillets we extract all the faces.

• Hide the Class A and Untrim the Extracted sides.

• Extrapolate the sides so that all the 3 faces touch eachother.

• All the faces are offested downwards of 2.5mm from the class A.

• Trim the faces so that it forms a replica of Class A.

• Fillets are measured by extracting and untrimming the fillet portion of Class A.

• Apply the fillets and hence we form the Class B surface. Give different color to identify the Class B surface easily

C SURFACE:

• The outer edge of the Class A surface is taken as reference boundry.

• Smooth curve is applied where ever needed to get a better surface.
• Sweep is used and extended downwards with 4 degree as draft outwards.

• It is then extrapolated and trimmed so that we get the Class C surface

FINAL PART:

• So now we have Class A, Class B and Class C surfaces.
• We can join the Class A and Class C surface now.
• Trim the Joined section with Class B.
• Here we form the enclosed section of the part.

DRAFT ANALYSIS:

• Draft is done on the Final Part. 
• Change it to material in customise view.
• Click the Draft analysis tool and click the surface and align the compass to tooling axis.
• 3 degree is the clearing angle.
• So here is photo of cleared (Green) draft

CLOSED BODY:

• Open the Part Design.
• Use the closed body command and create a solid Body of the Switch Bezel.

CORE AND CAVITY DESIGN:

CORE DESIGN :

• Retangle sketch is drawn and it is extruded. 
• The extruded section is trimmed with parting surface with component

• The top opening is closed with fill command.
• This is the Core closed section

• Part design is switched and closed body is formed

CAVITY DESIGN:

• The sketch drawn for core is used to create the extrude of cavity.
• It is then trimmed with the B Surface

• The lower portion of opening is closed with fill command and joined

• It is then formed into closed body with part design 

PARTING LINE :

• It is created with intersection of B surface and Join of A and C surface

PARTING SURFACE:

• Parting surface is created by taking boudry of Class A surface and extrapolating it

• It is then Trimmed with C Surface

• Trimming is done with B surface and Previous trim so that we get Parting surface with component

• Split is done with Parting line so that we get the Parting surface

DRAFT ANALYSIS:

• Draft is done on the Core and Cavity. 
• Change it to material in customise view.
• Click the Draft analysis tool and click the surface and align the compass to tooling axis.
• 3 degree is the clearing angle.
• So here is photo of cleared (Green) draft

Here are the Photos of Core and Cavity