Week 8 - Challenge 6 - Core & Cavity Design

Aim :

To A Create the Core & Cavity For The Switch Bezel Plastic component through the given Class-A surface. 

Objectives :

To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. 

Take the Thickness of the component to be 2.5 mm

• Tree Structure
• Ensure Proper Tree Structure
• Geometrical sets should have a proper name based on the sketches present inside of it
• All the sketches should be created under the Geometrical set 
• Use the Close Surface feature to make a solid body from the surface. 
• Publications: Use the publication option and publish the below
  • Tooling Axis
  • Class A, B, and C surface

• A detailed report should be done explaining the draft analysis and the tooling axis creation. 
• An explanation should be given on the way of creating the tooling axis, particularly the Bisecting method. 

• Screenshots of the Draft analysis report for both the given Class-A surface and the final plastic component
• Screenshots of the solid model with the proper color code of the draft angle in various orientations (Isometric, Front, Side, and Top View)

Procedure :

• 1.First Thing is open the CATIA V5.
• 2.Open the given file "Core & Cavity For The Switch Bezel Plastic component CATpart" then check if the geometrical set is properly arranged or not.
• 3.Then go to the Surface workbench 
• 3.Give the proper Tooling Axis.
• 4.After that work on the Core & Cavity For The Switch Bezel Plastic component Geometrical Structure.
• 5. Ensure to check the bondaries & join them properly.
• 6.Make sure that proper dimensioning is necessary 
• 7.Finally check if it is Iso Constrained (Fully Constrained) or not.
• 8. By Using Surface workbench to thicken the surface & Close them properly.

Let We Discuss in Detail Manner in Step By Step :

Class A Surface :

We Know that The Class A surfacing is the art in front of the engineering. It is the styling process brought in to digital life.

According to the given task we have to thickneed Class A Surface before that we need observe the Class A Surface carefully as shown in figure below.

Tooling Axis :

The tooling axis is a rotated an Angle 1 about the x-axis, then rotated an Angle 2 about the y-axis. Angle 1 about Z, Angle 2 about X. The tool axis is a rotated an Angle 1 about the z-axis, then rotated an Angle 2 about the x-axis.

In Practical based on the removal metal from core & Cavity we need a Centre of the surface that is we called as tooling axis.

Create A Dummy lines on A Bush or hole walls & Then Intersect them.

Bisecting Line:

In Geometry, a 'Bisecting line' that divides the line into two different or equal parts. It is applied to the line segments and angles.

use of those 2 dummy from intersecting sketch create the bisecting line as shown in figure below.

Publications & Tree Structure :

“Publishing geometrical elements is the process of making geometrical features available to different users”.

“A publication acts as a reference to a geometric or datum entity in a CATIA V5 part or product”.

slecting the geometrical elements for easier to show or hide  when we work on the catia so that we have to select the Class A,B,C Surfaces & Tooling Axis, after that go to the tools & Select the publication Click yes & Click ok, then we got the publication on the tree As shown in figure below.

CLOSE SURFACE SOLID BODY :

A closed surface contains a volume of space, enclosed from all directions.

Go to the part design workbench & Click the close surface command & click the final trim surface component then the close surface solid body formed as shown in figure below.

We Know that We Had Taken this from Previous Switch Bezel CatPart & Then We Have To Create the Core & Cavity Blocks .

Core & Cavity :

Core and cavity are the two halves of complete mould in which either of them is fixed and other one is movable. During injection moulding, core and cavity is pressed against each other tightly to create hollow space and avoid leaking of material. The surface where the two halves are joined is called parting surface.

Parting Surface :

Extrapolte From Class A & Then Trim With Class B&C Surfaces Then We Go the Parting Surface as shown in figure below.

Core Geometry :

Extrude & Fill the Surface by taking the sketch on axis with respect to parting surface & Then Trim it We may got the Core geometry as shown in figure below

Cavity Geometry :

Extrude & Fill the Surface by taking the sketch on axis with respect to parting surface & Then Trim it We may got the Core geometry as shown in figure below.

CLOSE SURFACE CORE BODY :

A closed surface contains a volume of space, enclosed from all directions.

Go to the part design workbench & Click the close surface command & click the final trim surface component then the close surface solid body formed as shown in figure below.

CLOSE SURFACE CAVITY BODY :

A closed surface contains a volume of space, enclosed from all directions.

Go to the part design workbench & Click the close surface command & click the final trim surface component then the close surface solid body formed as shown in figure below.

INTERSECT :

PARTING LINE :

The parting line of a die cast component represents where the two different sides of the mold come together. This line often (but not always) marks the border between the inside and outside of the part.

TRNALATE THE CORE & CAVITY BODIES:

The translation feature is used to moves an object a certain distance for observe the mould operations as shown in figure below.

Draft Analysis :

So lets discuss about the draft analysis

The Draft Analysis allows the user to easily analyze a part for proper draft angle. A Draft Angle describes the amount of taper for molded or cast parts perpendicular to the parting line.

We have 2 modes on the draft analysis Quick & Full analysis respectively.

Under the Display option we have Show are hidden the Color Scale, Analysis under the running point, No Highlight representation & Light effect.

Under the Direction option we have lock or unlock the direction, Compass & Invert.

So According to the practical Usage there Should be 1 to 3degree of angle mostly acceptable, by considering these option we have to test our given & Final Components Draft analysis.

Draft Analysis On Class A surface :

Draft Analysis On Class Final Component :

Draft Analysis On Closed Surface Solid Body :

Hence observe that the above screenshots have Fully Defined, Expanded Tree Structures & Snaps in various orientations. 

Conclusion:

Successfully Created Core & Cavity Blocks For the Switch Bezel Plastic component through the given Class-A surface.