Week 8 - Challenge 6 - Core & Cavity Design
CREATION AND EXECUTION OF TOOLING AXIS, DRAFT ANALYSIS FOR PLASTIC COMPONENT WITH PARTING LINE AND SUFACE USING CORE AND CAVITY MOULD CONCEPT
(SWITCH BEZEL)
OBJECTIVE:
The main objective is to create a tooling axis and draft analysis for the plastic component design using CATIA V5. The design of plastic surfaces includes CLASS A SURFACE, CLASS B SURFACE and CLASS C SURFACE. Combination of these three includes the Solid conversion of plastic components.
TOOLING AXIS: It is the area where the direction in which the mould open.
STEPS TO BE FOLLOWED ARE;
STEP 01 – CLASS A SURFACE INSERT
Insert a basic component like no thickness element into catia v5 and name it as Class A surface and check for the boundary condition. The boundary condition is used to identify the continuity of the component.
STEP 02 – DUMMY TOOLING AXIS CREATION
After the class A surface insert make sure that the tooling going to takes place in which area and direction. Then make the axis using point and direction method and convert into dashed line for easy axis. Here two sketches are going to take place for creation of tooling axis. The sketch 1 must face the front side of the aesthetic and the sketch 2 will be face the side view of the object.
STEP 03 – MAIN TOOLING AXIS CREATION (BISECTING LINE)
After this steps make the two lines bisecting with each other with the help of two sketches and create a wanted length between both top and bottom of the object. Now make the line format into wanted dashed line to identify easily.
STEP 04 – DRAFT ANALYSIS
By using draft analysis we may find the draft angle is maintaining at 3 degree or not. By using draft analysis symbol in catia open the tool box and insert the compass into the main tooling axis and check the draft angle deviation by using the analysis check point option and finally select the object where the analysis takes place. Now the analysis part area may change into green colour and below of that green it may appear like blue it indicates it is a negative value.
STEP 05 – PUBLICATION
Publication is to publish the main things into a separate tree structure. Is used to maintain the things as highlighted while designing.
STEP 06 – CREATING CLASS B SURFACE
Class B surface is the extraction of shape and structure from class A with the help of surface shape features with the deviation of 3mm difference between the class A and B surface. By using the extract tool feature this can be achieved by using step by step.
STEP 07 – CREATING CLASS C SURFACE
Class C surface is the parallel wall thickness of the tooling axis. It also created by using the class A surface boundary area. Then the sweep option is used to create a wall thick by using 3degree deviation angle as shape and it must be facing outwards as direction.
STEP 08 – COMBINE OF CLASS A, B AND C SURFACES
Final step of the surface create is combination of A, B and C surfaces. Now make the trim one by one from A and B surface and remove unwanted areas from the respective surfaces. After all this join the trimmed surfaces into one form with the help of join option and name it as final surface.
STEP 09 – CONVERT TO SOLID
Now convert the surface to solid form by using close surface option in a new body.
STEP 10 – DRAFT ANALYSIS OR FINAL SOLID PART.
Repeat the same draft analysis procedure from surface and make sure that the part may take the same draft compared to class A surface.
STEP 11 – CREATION OF PARTING SURFACE
After the completion of solid conversion make the new geometrical set and name it as parting surface. Show the CLASS A surface and make the outer edge into 15 mm explode. Now the CLASS C surface is going to interact the class A surface so go for trim to achieve the shape with respect to CLASS C surface.
STEP 12 – CORE AND CAVITY MOLD CREATION
Now make one rectangle shape with covering the top area of the shape and make it into a complete profile and create a solid form with the help of PARTING SURFACE as reference. This setup is called as CORE MOLD.
Now make the same rectangle shape with the help of CLASS B surface as top and complete the part with closed solid form. This setup is called as CAVITY MOLD.
CORE MOLD
CAVITY MOLD
CORE AND CAVITY MOLD WITH FINAL PRODUCT
STEP 13 – CREATION OF PARTING LINE
Parting line always at the CLASS B surface. These line is going to intersect with the CLASS A and CLASS C with respect to CLASS B surface as input. Parting line indicated the extra projection of part so that is the reason mostly we are using 3degree angled draft as a main input.
CORRESPONDING VIEWS
