Week 8 - Challenge 6 - Core & Cavity Design

Core and Cavity Report

Aim:

• To create Core and Cavity for the given switch bezel.
• To create parting line and parting surface.

Objective:

Switch Bezel

• To create the Final Solid Part by using the given Class A.
• To create the Tooling Axis for the Class A and Final Solid Part.
• To Draft analysis the obtained Final solid part and Class A using the created Tooling Axis.

Core and Cavity

• To create Core and Cavity for the given switch bezel.
• To create parting line and parting surface.

Introduction

Tooling Axis

• The Tooling Axis is to show in what direction does the core and cavity moves.
• It also created to give a draft angle for the final solid part.

Draft Analysis

• The draft analysis is done on the basis of the Tooling Axis in order to find whether the final product is done as per the Design rules.
• The Draft angle which is assigned to the Tooling Axis defines the analysis.
• The Nominal Draft angle for the plastic product is 3 degree.

Class A

• Class A is the aesthetic surface.
• Class A is created on the basis of a concept sketch or by the predefined shape on basis of the design engineer and customer requirement.
• Class A is given to the Product design engineer in order to get the final solid part.

Class B

• Class B is the surface that is created by the product design engineer in order to get the final product from the class A surface.
• Class B is created based on the thickness that the final solid part should be.
• In other words, Class B is an Extended version of Class A with some thickness gap between them.

Class C

• Class C is the surface that is designed by the product design Engineer.
• Class C is created inbewteen Class A and Class B in order to connect them.

CAVITY

• Cavity is known as the ‘Female-Section’ of the mold that creates the external shape of the plastic component.
• It belongs to the fixed-half section of the mold-unit.
• It is usually formed by removing metal from the mating surfaces of the two halves.
• Molds can contain a single cavity or multiple cavities to produce more than one part in a single shot.

CORE

• Core is known as the ‘Male-Section’ of the mold that creates the internal shape of the plastic component.
• It belongs to the moving-half section of the mold-unit.

Parting surface

• Parting surface is layer between the core and cavity of a mold.
• If the parting surface is not designed properly the product which comes out of the mold will have defect.
• It should be tightly closed so the molten material will flow in correct path.

Parting line

• Parting line is a line where cavity meets the component.
• In other words parting line is extactly where cavity and core touches with product.

Procedure:

Switch Bezel

Class A

• The class A is taken as given Catpart file.
• Created class A is checked with the boundary tool.

Tooling Axis

• The tooling axis is created using bisecting method.
• Bisecting method is one method for creating the tooling axis where tooling axis created by intersecting two line.
• The axis is created by extrectin the surface and creating a point on the surface.
• The two line, one line is created from the intresect of created y-axis and class A.
• The second line is from intresect of created z-axis with class A.
• Then orginal tooling axis created.

Draft Analysis on Class A

• The draft analysis is done on class A with the help of tooling axis.

Class B

• The class B is created by offsetting the derived Class A to 2.5mm.
• The Faces of class A is Extracted and untrimed sperately.
• It is done seperately due to fillet that will not be proper when offset.
• The untrimed faces are offseted.
• The trimed together and Edge fillet operation done.
• Thus the class B is derived.

Class C

• The class C is created from the class A using the sweep.
• The boundary of class A is taken.
• Then 'with draft direction' is selected in the sweep tool.
• The tooling axis is used for draft direction and boundary as profile.
• The Class C is created.

Final operation

• The Created class C is joined with the class A.
• The joined class A and class C is trimed with class B.
• If class A and class C join can't be trimed with class B then extrapolate the class B to some millimeters.

Solid Body

• The solid body created by using closed surface.
• The design which created is switched from 'genrative shape design' to 'part design'.
• Then closed surface tool is used to convert the plastic design model to solid form.

Draft analysis

• The draft analysis on solid body is done.
• The draft analysis show the created solid is done as per design rules.

Core and Cavity of Switch Bezel

Parting Surface

• The parting surface is created by design rules.
• It is created by joning the class A and Class C.
• Then triming it with class B.
• The parting surface shows us where does the core and cavity are going to meet.

Core block

• Core block is where the required compenent impression will have init.
• Then for the creation of core block a sketch of rectangle is created and it is extruded.
• The extrude done in the tooling axis direction.
• The extrude is then trimed with parting surface.
• The Core block trimed in the upward direction.
• There is open in the top it closed with extrude process.
• Both the extrude are joined together to form the closed object.

Cavity block

• Cavity block is where the required compenent will be covered.
• Then for the creation of Cavity block a sketch of rectangle is created and it is extruded.
• The extrude done in the tooling axis direction.
• The extrude is then trimed with parting surface.
• The Cavity block trimed in the doenward direction.
• There is open in the bottom it closed with extrude process.
• Both the extrude are joined together to form the closed object.

Core and Cavity Solid

• The Created core and cavity surafce block is checked for any opening.
• Then it is converted to solid by switch from 'generatiive shpe design' to ' part design'.
• The 'closedsurface' option is used to get solid.

Isometric view

Front View

Side View

Top View

Parting line

• The parting line is created by intersecting method.
• The class A and Class C join is taken and intersected it with the Class B.
• The line which is formed is called parting line.

• Then translate option is used.
• Inorder to show the component, parting surface and parting line in between the core and cavity.
• The Core is translated upward and Cavity is translated downward.

Srtuctural tree Images

Conslusion

• Thus the Core and Cavity for the Switch Bezel is created.
• The Parting surface and parting line created in accordance with it.
• The draft analysis for the Switch Bezel surface and solid is done and its satfies the design rules.