Week 8 - Challenge 6 - Core & Cavity Design

AIM:

• To Create the Core and cavity blocks for the switch bezel component.

DESCRIPTION:

1. CREATING TOOLING AXIS -

The Tooling Direction is basically the direction that the mold pulls a part. The mold is built in two separate pieces, basically. You have a Cavity side and you have the Core side. The Core pulls apart from the Cavity and that's the Dye line or the Tooling Direction.

• Open the given CAT part file.
• Check for gaps between surfaces for that click on join and then preview.
• If theres any gap between the surfaces join them with a maximum tolerance of 0.003 mm.
• Extract the boundary and dissemble the boundary.
• Find the correct tooling axis where the material don't interfere with the tooling axis and all the elements can be created.
• Create an axis system using at the centre of the switch Bezel
• Intersect the yz plane with respect to the class A surface.
• Hide the class A surface and create point to point lines on the suspected drafts.
• Create bisecting line with the two lines and point to create a tooling axis.
• BISECTING LINES were used to get the exact medium from the two sides so that maximum positive draft angle can be achieved.
• The tooling axis is created for the component by bisecting two axis from x and y planes.

Core and Cavity Design:

The mold core and cavity are shaped sections in either half of the mold tool which give the plastic product its final shape. The hot molten material is injected into the core and cavity and then sets hard into shape. The design of the core and cavity is essential in the correct formation of the product. The sequence of events during the injection mold of a plastic part is called the injection molding cycle. The cycle begins when the mold closes, followed by the injection of the polymer into the mold cavity. A core is usually made of the best quality sand and is placed into the desired position in the mold cavity. Core prints are added to both sides of the pattern to create impressions that allow the core to be supported and held at both ends.

3. DRAFT ANALYSIS

The Draft Analysis command enables you to detect if the part you drafted will be easily removed. This type of analysis is performed based on color ranges identifying zones on the analyzed element where the deviation from the draft direction at any point, corresponds to specified values.

• Before going to drat analysis go to customized view parameter >under mesh >check material and then click ok.
• Now for draft analyses go to insert » analysis » feature draft analysis.
• Use the compasss to define the draft direction.
• In the colour scale change the draft angle to 3 degree.
• The component changes to green in indication of passing draft angle.
• Use running point to check the angle on the component.

Conclusion:

Thus core and cavity is created as per the given part profile along tooling Direction.

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