Week 8 - Challenge 6 - Core & Cavity Design

Aim:Create the Core and cavity blocks for the switch bezel designed.

Draft analysis report for both the switch bezel plastic component :

Draft :

Draft angle is nothing but providing some tapered portion to the part for easy removal of the component from the mold during manufacturing. This is especially done in the case of plastic component design having a complex shape. Mostly the 3-degree draft angle is provided but it can vary depending upon the component which is to be designed

In our case of Switch Bezel design, the draft angle is 3 degrees the draft analysis is done during the design of the component to check the feasibility of the product.

Before providing a draft angle we need to decide on the tooling axis also known as the molding axis considering the faces which can cause issues while manufacturing.

Tooling axis :

It is nothing but the direction in which the mold opens and closes the draft angle needed to be provided by considering this tooling axis.

We can create a tooling axis by using the bisecting method.

Bisecting Methode :

This method is used for the generation of the tooling axis for that purpose first we need to decide the direction of molding and then we create one dummy tooling axis for the reference to the purpose.

In this method, we select the surfaces which can create problems and take intersections in the x and y-direction. By using these curves we draw two lines and then draw a bisecting line from these two lines in the x-direction and y-direction.

If it is done in x-direction then it is called a tooling axis clearing x-direction and if in y then tooling axis clearing y-direction.

After completing this we need to draw a final line bisecting this two tooling axis in the X and Y directions to get our final output.

Draft Analysis of the Switch Bezel Plastic Component :

Core Block Isometric, Front, Side, and Top View :

Cavity Block Isometric, Front, Side, and Top View :

Isometric, Front, Side, and Top View :

Parting Line :

It is a line that splits the mold into two parts – the core and the cavity.

A parting line is one of the most fundamental concepts in injection molding (almost any type of molding, actually), and in designing components for manufacturing using these methods.

The mold used to form the cavity that the material will be injected into needs to come apart so that the component can be removed and the mold can be used over and over again. In the simplest embodiment, the mold is made up of two sides, and there is a single continuous seam, a line, around the perimeter of the component. This line is usually visible as a slight discontinuity in the surface of the component after it is removed from the mold.

Partin surface :

A parting surface is a surface that separates the mold block into two parts – the core and the cavity.

The parting surface is the surface of the mold that is perpendicular to the parting line. The purpose of the parting line is to separate the two halves of the mold so that the molded part can be ejected by the ejector pin.