Challenge

Week 8 - Challenge 6 - Core & Cavity Design

Aim:

This project aims to create a Core and Cavity for the Switch Bezel Component and perform the draft analysis for Switch Bezel.

CREATION OF TOOLING AXIS:-

Considering the Ejection from the cavity of the mould after manufacturing the interior trim (switch bezel) must have the nominal 3-degree draft angle.
Hence the tooling direction is created by considering the above factor and bisecting method is used.
The base surface of the class – A was extracted and a point at the centre is created and an axis system was inserted to the point with the current feature is disabled.
Then, using project intersection along yz plane is created and the two inclined lines were drawn inside the positioned sketch.
Then bisecting lines with the two inclined lines were drawn.
Now the same procedure is done along the xz plane but on one side we don’t have inclined lines so the centre point is used to extrude a line along the z-direction and gave a measurement of 6 degrees (Tentatively).
With these two lines from sketches 1 and 2, the bisecting line is crated and published as Tooling Axis(tooling direction).

CLASS-A SURFACE:

The class-A surface is used in the automotive design industry. it describes the final production surface data for the aesthetic parts.

DRAFT ANALYSIS ON CLASS-A SURFACE:

Go to insert> analysis> feature draft analysis
Align the tooling axis with the compass.
Click on the surface and see that the surface is within the permissible limit of the draft values.
The surface should be green and in the column nominal value 3deg given as input. hence the draft analysis on the class-A surface is successfully performed.

CREATION OF CLOSED SURFACE:-

Now the class – A and Class- C surfaces were joined together by removing the gaps in-between them with the help of extrapolation(tangent continuity) and Trim surface.
Then the exact surface of the Switch bezel was trimmed from the above-resulted trim surface with the class-B surface.
Then, by defining the part body by using the Closed Surface command in Part Design, the component's solid body is created.

DRAFT ANALYSIS ON CLOSED SURFACE:

First the class – A surface is checked before creating the Class –B&C surface and finally the solid body must be analysed. Both can be done by following the below procedures.
By changing the view mode to custom view parameters – Material mode then the feature draft analysis is enabled.
Then the compass was activated and placed with the tooling axis by dragging the red pointer and then locked it.
Then, by selecting the quick analysis mode, the nominal value will be 3 degrees and checked for the component's draft angle.
The green colour area shows that it satisfies the 3-degree draft angle. If not satisfied then by using the Running point tool the area is measured and then altered to get a successful draft for the created tooling direction.

CORE AND CAVITY design for switch bezel:

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.

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.

Core & Cavity:

The core & cavity are the shaped sections in either half of the mould tool which give the plastic product its final shape.
The hot molten material is injected into the core & cavity and then sets hard into shape.
The design of the core & cavity is essential in the correct formation of the product.
Core is an extended or male portion of the mould which creates the internal plastic part surface
Cavity is a depression or female portion of the mould which creates the external plastic part surface.

CORE BLOCK: