Week 8 - Challenge 6 - Core & Cavity Design

CHALLENGE 26 – CORE & CAVITY DESIGN

Aim: Given completed Switch Bezel Design, complete the design of the core and cavity for the switch bezel component.

COMPLETED SWITCH BEZEL COMPONENT

We were provided the completed Switch Bezel as below.

Fig 1 – Original Switch Bezel Component

We then created a Tooling Axis by bisecting two Sketch lines, as below.

Fig 2a – PARTIAL TOOLING AXIS SKETCH

Fig 2b – PARTIAL TOOLING AXIS SKETCH

Fig 2c – TOOLING AXIS (Bisecting the Sketch Lines)

Thickened Part

After creating the Tooling Axis, we then created the Cavity and Core based on the Completed Switch Bezel Class A, B and C surfaces. We then translated the Core and Cavity to show the tooling at open position.

Feature Tree

Fig 3 – Feature Tree

VIEWS

Core

Below are four views of the final Core part (Iso, Front, Side, Top):

Iso

Fig 4a - Iso

Front

Fig 4b - Front

Side

Fig 4c - Side

Top

Fig 4d – Top

Cavity

Below are four views of the final Cavity part (Iso, Front, Side, Bottom):

Iso

Fig 5a - Iso

Front

Fig 5b - Front

Side

Fig 5c - Side

Bottom

Fig 5d – Bottom

Draft Analysis

Fig 6 -- DRAFT ANALYSIS OF SWITCH BEZEL

Iso

Fig 6a - Iso

Front

Fig 6b - Front

Side

Fig 6c - Side

Top

Fig 6d – Top

The Draft Analysis as shown above validated the design for manufacturability.

FINAL TOOLING

Below is the final tooling assembly with Core, Cavity and Finished Component.

Fig 7 – Final Tooling Assembly with Core, Cavity and Finished Component

Conclusion: We were able to successfully model the Core & Cavity and verified the Switch Bezel for Draft Analysis.