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.
• Publication is done to the component to make it visible and navigate easily.
• To publish the component go to tools > publications and then select the tooling axis and the class A surface.
• A separate tree structure is formed under the main part.

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.
• Before going to drat analysis go to customized view parameter >under mesh >check material and then click ok.
• 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.

• The draft analysis is complete.

4. PARTING SURFACE

• Generally injection mold has two major components : the movable half and the fixed half, during the injecction molding process, these two halves are pressed tightly from a sealed hollow to avoid the melt flow leakage and maintain certain holding pressure, the pressed surface are called parting surface , usually parting surface are the biggest projection outline of the part.

5. PARTING LINE

• A parting line is an inevitable part of injection molded products.
• It is the line of separation between where two halves of a mold meet.
• It manifests itself on injection molded parts as a line that runs the entire perimeter of the part.
• In most parts, it is just a line that runs straight down the middle.

6. CORE DESIGN

• Core - A portion of the mold that goes inside a cavity to form the interior of a hollow part.
• Core-cavity - A term used to describe a mold created by mating A-side and Bside mold halves.

7. CAVITY DESIGN

• A mold is a hollow form typically made from stainless steel that has plastic injected into it to manufacture a plastic part.
• The plastic is inserted into the mold cavity, which is a hole in the mold shaped like the desired part.

8. 3D VIEWS

• ISOMETRIV VIEW