Week 8 - Challenge 6 - Core & Cavity Design

CREATION OF THE CORE AND CAVITY BLOCKS FOR THE SWITCH BEZEL

Generally, the part component that we design must be toolable or manufacturable. As we know that some exterior and most interior parts of automotives are made of plastics. In that 80% of the plastics are manufactured by Injection molding. Injection molding have two halves- Core half and Cavity half, in which one is movable and the other one is fixed. To be manufacturable by Injection molding, all faces of the plastic part component must clear the main tooling axis direction and there are exception in which sidecores are used additionally if holes and slots are present in the part component.

There are three ways to find the tooling axis direction-

1. X, Y, Z axis method

2. Bisecting method

3. Normal to surface method

I have found the tooling axis direction of switch bezel by using bisecting method. Generally if holes or large flat faces are present in the part component, the normal to them will be tooling axis direction. To be toolable or manufacturable, all faces of the part component must clear the tooling axis direction. The faces that are parallel and perpendicular to the tooling axis direction would be cleared with ease. The faces that is in a angle( Acute or Obtuse) will be bisected in order to get to get the tooling axis direction.

Tooling axis direction of switch bezel-

Parting surface of switch bezel-

Parting line of switch bezel-

Draft analysis-

It is a technique that is used to analyze whether our part component that is designed in the catia part workbench can be manufacturable based on the draft condition applied.

The nominal draft angle value is 3 degree

Draft analysis of Class A surface:

Draft analysis of part component:

Core block of switch bezel-

Cavity block of switch bezel-

Core and Cavity blocks in different orientations-

Isometric view

Front view

Back view

Left view

Right view

Top view

Bottom view