Week 8 - Challenge 6 - Core & Cavity Design

1. OBJECTIVE:

Create the Core and cavity blocks for the switch bezel designed

2. Definitions

Class-A Surface:

Class A surface is made from scanned data with different software like allias etc.. lass A surface having CURVATURE CONTINUITY

Class-B Surface:

Class-B surface having all features(Rib,boss,snap etc). It is created by extracting the all wall of the Class-A surface.

Class-C Surface:

Class-C Surface is used to joining the Class-A Surface & Class-B Surface. This surface is generated by sweeping the Class-A surface boundary.

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

Tooling axis

Tooling axis is tells about the in which direction core should be move. This tooling axis creating by line with normal to surface method.

3. Procedure

3.1 Tooling axis making

• Extract the surface from the base.
• Create center point in extracted surface.
• Make a line line with normal surface from the centre point of the extracted surface. And named as a tooling axis

3.2 Draft analysis for Class-A Surface.

• Insert--->Analysis--->Feature Draft Analysis
• Draft analysis window will appeared. In that using the compass and define the new current draft direction.
• Locked the draft direction.
• And then click on the surface.
• Color coded on the surface with reference to the draft angle.

Green for 2.9°,

Blue For 0°

Red for Below 0°

3.3 Draft analysis for solid model.

• Insert--->Analysis--->Feature Draft Analysis
• Draft analysis window will appeared. In that using the compass and define the new current draft direction.
• Locked the draft direction.
• And then click on the surface.
• Color coded on the surface with reference to the draft angle.

Green for 2.9°,

Blue For 0°

Red for Below 0°

3.4 Creating core and cavity blocks

• Extraplote the Class-A & C surfaces, and trimmed with each other
• Class-A&C surface trim with Class-B surface.
• Create the rectangle and extrude with draft direction.
• And the then trim with Class-A+B+C.
• Remaining open surface close with fill.
• And the converted into solid by using close surface. And named as core block.
• Same procedure applied for making cavity block.

4. Result

Initially Tooling axis was created by Line with normal to surface method. And the draft analysis is applied for class-A surface. After that Created the Switch Bezel Plastic component through the given Class-A surface with 2.5mm thickness. Now draft analysis is applied for plastic component of Switch Bezel and draft direction was found satisfactory.