Week 8 - Challenge 6 - Core & Cavity Design
- Title of the Project:
Design of Core & Cavity mold for the Switch bezel Plastic component,using Class-A surface data in Catia V5.
- Objective:
To model the core and cavity for the switch bezel plastic component, through given surfcace data, by creating tooling axis and perform draft analysis for the generated model.
- Methodology:
- Class A Surface continuity:
It is the initial stage, such that the class A surface input data is verified for its continuity, and ensures that there is no discontinuity in surfaces.
- Creation of tooling axis:
Initially analysing the model visually to check which direction would be most optimum for tooling axis, such that it would result in gaining better product with optimum cost, by selecting the X and Y axis planes an intersection is generated. Using the bisecting lines the intermediated tooling clearing along their direction is generated. Using this tool clearing direction lines, the actual tooling axis is created for the switch bezel.
- Creation of Class B surface:
Class B surfaces are the surfaces which consists of engineering design features for the class A component.it may consists of ribs, latches, fits, stiffener etc. initially the class A surfaces are extracted and individually and offsetted to certain distance and using surface features exact replica of class A surface is generated.
- Creation of Class C surface:
Class C Surfaces are the surfaces which connects class A and B surfaces together to form a single model. This surface is generated using sweep option by giving the desired draft angle for the model and it is blended with class A and class B to form a complete design of the component.
- Performing draft analysis:
Draft analysis is performed on a component in order to identify whether there is any negative and positive angle is involved in the component.This draft angle allows the part to eject easily from the mold (Core & Cavity). The draft angle reduces the friction between mold and the part.it also tends to avoid the damage occurring to the mold and part during ejection processes frequently used draft angle is 3 and minimum draft angle is 0.5.
By applying the material to solid model, draft analysis is done by aligning the compass to the tooling axis and minimum and maximum draft angle is entered to get the desired result on the model. After interpreting, if there are any negative draft angle is identified, then the tooling axis or the model needs to be isolated for further design correction.
- Creationg of Core & Cavity Surfaces:
By extracting the lower outer surfaces of the switch bezel,the cavity side of the mold is been generated,and by extracting the upper side of the switch bezel surfaces, core is been generated.once the core and cavity surfaces are generated they are thicken and translated to an extent to plot the mold design.
- Converting of Surfaces into solid:
After designing the complete surface model of the core and cavity,using the close surface option, the surface model is converted into solid model.
4. Modelled Components:
Isoview
Front view Side view Top view
- Conclusion:
Based on the requirement, the design of core & cavity for switch bezel Plastic component is modelled through Class-A surface, by creating the tooling axis. using class A surface and solid component draft analysis is performed for the component using Catia V5. The results ensures that there is a manufacturable draft angle involved in the model. This concludes that, the part design can be manufactured easily by incorporating tooling axis during its production.