Week 8 - Challenge 6 - Core & Cavity Design
1-SWITCH BEZEL CLOSE BODY DESIGN
TOOLING AXIS – First of all I received the class A surface. I extracted the base surface then I created the point using surface after I took the axis system on point. By using axis system, point and position sketch I created two sketch. In first sketch I created a bisecting line using two side wall lines. In second sketch I created a line which was 3 degree to wall line. All the wall line created by intersect 3d elements. At last I created the bisecting line using both sketch and named it as tooling axis. After creating the tooling line I check the tooling line is right or not and take feature draft analysis but there were some angle issue so I take the axis system on the point again and create the line by angle/normal to curve and pick the curve as tooling lineand for support zx axis and for point I pick the point 1 and give the angle negative 2 degree. At last I named it as main tooling line.
Draft analysis 1 – I inserted the draft analysis for class a and give the draft angle 2.9 degree . I took the compass on tooling line and lock that and pick the a surface. After picking the surface a one surface goes fully blue and second one turns into fully green that’s mean my tooling line is perfect.
B SURFACE – I had created b surface in several phases.
1 BEZEL REST SURFACE – I extracted the bezel rest surface and untrim that and extrapolate it by 25mm. After that I offset it by 2.5mm which is the thickness of component.
2 WALLS – I extracted the side walls and untrimmed them after that I extrapoled them one by one with curvature continuity and prapogation mode point continuity give the extrapolate value as 30mm. at last I offset them by 2.5mm out side of class a.
3 BASE – I am extracted the base surface and untrim that. After that I extrapolated that and offset it by 2.5 mm. at last I trim all together and created a surface. After that I measure the fillets, for one fillet I extract that fillet surface and untrim that and measure the fillet value. After measuring fillets I gave it to surface and finally I got a surface and named it as b surface.
C SURFACE – In c surface I extract the boundary in two multiple extract command and created two different sweep surface with draft direction and select guide curve as multiple extract 1 and draft direction as tooling line. For second sweep I do the same as first but for guide curve I gave the multiple extract 2. After that I got two sweep surfaces but in those two surfaces there are some gap so I extrapolated them and trim together at last I got a surface and named it as c surface.
FINAL TRIM – After creating the b and c surface I join the c surface with class a. At last trim the join with b surface and I got close surface.
CLOSE BODY – When I got the close surface then go to part design and choose the close surface command and pick the close surface to close it. There I got the close body.
DRAFT ANALYSIS 2 - I put the close body in to material mode and take the feature draft analysis. I took the compass at tooling line and pick the close body. When I pick the close body it turns into one side blue and one side green.
2-SWITCH BEZEL CORE AND CAVITY DESIGN
FOR CORE AND CAVITY I CREATED IT IN SEVERAL PART`S.
1- PARTING SURFACE – (a)For parting surface I take the boundary of class a and extrapolate it by 22mm with curvature continuity after that I trim it by c surface and I got the trim 4. After that I trimmed the trim 4 with b surface in got a surface and named it as parting surface with component area.
2-CORE DESIGN – For core design I created a sketch of rectangle for chop the parting surface with component area and extrude it by 182mm and trimmed it with parting surface with component area and take boundary of upper hollow surface and fill it after filling I joined it with trim 6.
3-CAVITY DESIGN – For cavity design I take the sketch 3 and extrude it in lower of class a by 186mm and trimmed it by parting surface with component area. After that I take the boundary of lower hollow surface and fill it then joined it with trim 7.
4-PARTING LINE – For parting line I take the intersection of join 1 and named it as parting line because this is line witch is met the parting surface with component.
5-CORE BLOCK – For close the cavity I went to part design and take close surface command and pick the join 2 and I got core block. After that I translate it by 50mm.
6-CAVITY BLOCK – For close the cavity I went to part design and take the close surface and pick join 3 and I got the cavity block. After that I translate by -50mm.
7-INTERSECTION – For checking of the core and cavity output I take intersections with close surface2, parting surface with component area, close surface1 and close surface 2.
8-PARTING SURAFCE – (b)For parting surface I split the parting surface with component area by parting line then I got a surface and named it parting surface.