Challenge

Week 8 - Challenge 6 - Core & Cavity Design

CORE AND CAVITY DESIGN ON SWITCH BEZEL

To design the core and cavity for the solid switch bezel and do a draft analysis for the same.

Steps followed

After receiving the class A surface check the connectivity of the surface and ensure it is completely joined and there will be no gap between the surfaces.
If it is not join together make it with a minimum tolerance of 0.001 to 0.003 and check for connectivity of the surface.
Connectivity of the surface can be done by two ways by join method and by boundary method.
Split the surfaces into multiple profiles then Identify the surface where it is not possible to create a tooling axis and check which direction is best fit for tooling axis and then define the tooling axis and draft direction.
Here for defining the tooling axis first we have created a point at middle of the base surface and create an axis with respect to that point then define the tooling axis using the intersect method by creating a bisecting line.
Then do a draft analysis on the class A surface and identify the draft angle then give the nominal value for the draft.

Tooling axis creation

The direction in which the mould open and closes is called the tooling axis direction.
Check the connectivity of the surface and ensure there will be no gap between the surfaces and then define the tooling axis.
While creating a tooling axis please ensure to give the tooling axis on a flat length surface or the surface which have a hole on it.
Create a point on the middle of the base surface by using point on the surface command then create a intersection for the surface and extract the reference lines which will be helpful for creating the dummy tooling axis using the intersect method by creating a bisecting line..
Use the line command and draw the lines which is aligned with the extracted lines and extended it to the required length.
Bisecting method
Identify on which plane we have to do more operations and create the plane or axis on the component area define it on the dummy tooling axis direction.
Intersect the class A surface with that plane then we will get a intersection sketch. Look for the profile (inclined line) which will create a problem and extract it then extending it by using line command.
Then create a bisecting lines with reference to the lines we have extended and this will be our main tooling axis.
In this case we have created two dummy axis along with Y direction and Z direction then we have created a line by using bisecting option and this will be our main tooling axis.

Draft analysis

Draft allows for the component to release from the mould, most parts or applications require a minimum of 0.5 to 1 degree draft angle and 3 dgree draft angle is widely used as per the norm.
Change the material mode to customize mode before moving to the draft analysis.
Insert –analysis-feature draft analysis
Defining the draft direction Select draft analysis from the tool bar and click on the compass symbol and pull the compass from the right side top corner of the workbench and place it on the component where want to do the draft analysis. ‘W’ of the compass and tooling axis should be aligned on the same line.
Once the compass is aligned with the tooling axis click on the lock symbol and drag on the surface we will get a wrong mark then select that point a table will appear it shows the draft value on the table we can adjust the draft value and analysis it for all the edges and surfaces.
By clicking the on the surface and using the flipping tool we can assign the Flipping direction, the color of the surface change as per the flipping direction .
Analysis under running point and move the mouse on the surface and it will show the details of the surface deg direct at each and every point of the surface.

By using the Class A, B and C surfaces we can create the core and cavity of for the switch bezel.

By using the Class A, B and C surfaces we can create the core and cavity of for the switch bezel.
Parting surface is first created by extrapolating class A surface and trim it with class C surface then create a boundary for the trimmed surface and extrude it.
To get the core we have to trim the extruded surface with the first trim and fill the uncovered area and join them together.
By intersection method we can check the parting line, parting surface, core and cavity geometries.
The solid body for the core can be created by using close surface in the part workbench.
The same method is used for creating the core and later translate them to get a clear view.

DRAFT ANALYSIS ON SOLID BODY