Week 8 - Challenge 6 - Core & Cavity Design

OBJECTIVE:

• To design the switch bezel from the given styling surface.
• Create the A-surface and tooling direction for the A-surface.
• Perform draft analysis on the A-surface.
• Create the B-surface and C-surface.
• Create the Core and Cavity for the Switch Bezel.

SOFTWARE USED: CATIA V5

DESIGN METHODOLOGY

Given: A-surface

• First, we need to check the given A-surface for any surface errors like open boundaries or twisted surfaces. We can use the boundary command to check for any open boundaries.
  
  

• TOOLING DIRECTION: Tooling direction is the direction in which the core moves away. It is necessary to find the tooling direction of the A-surface as the B and C surfaces will be created according to the tooling direction.
  
  To find the tooling direction we need to clear the inner walls of the Bezel for 3 degrees. Draft analysis is needed to check the angles of the inner walls.
  
  
  
  
• B-surface creation: For the B-surface, we create an extrapolated surface which will be cut using the C-surface.
  
  
• C-surface creation:
  
  
  
  
• Draft analysis on the closed body: Draft analysis on the body is performed to check the draft on the A-surface, B-surface, and C-surface. Here the Closing surface follows the draft of the A-surface.
  
  
  

Creation Of Parting Surface

• Class B and Class C surfaces are trimmed and is joined with extrapolated class A surface to obtain a parting surface with component area.
• If the obtained surface is splitted using the parting line, parting surface is obtained.

Parting surface with component area:

Parting surface:

Creation Of Cavity Block

• Cavity block created by initially drawing a rectangle which is to be extruded so as to make it able to trim with parting surface with component area. Thus, a box is obtained which is the cavity block.

Screenshots Of The Cavity Block In Various Orientations:

Creation Of Core Block

• Core block is obtained by trimming class B surface with the previously extruded surface. Thus, obtained below block is the core block.

Screenshots Of The Core Block In Various Orientations

CONCLUSION

• Created Tooling axis.
• Created Class B and Class C surface from provided Class A surface.
• Created solid part out of surface modelling.
• Draft analysis of Class A surface and final part is also done.
• Created parting surface for the part.
• Created core and cavity for the solid model.