Week 8 - Challenge 6 - Core & Cavity Design

Tooling Axis & Draft Analysis

Draft Analysis is used to analyse whether given product model is manufacturable or not. There is at least some minimum Draft angle should given for each and every product, so that the mould and part making minimum point of contact when the ejection time. It also reduces the part getting affected by the mould.

Here is the complete list of steps involved in Draft analysis for given model.

Class A Surface:

Procedure for creating draft analysis:

In the given class surface, have to check whether the given class a surface to clear the draft analysis, so that we have to decide whether the given product is manufacturable or not.

Creating a Tooling axis is mandatory for checking the draft analysis. On the reference of the Tooling axis only our draft analysis should perform. For creating tooling axis first analyse the given part in X, Y & Z view point and decide the maximum possibility to create the given part.

Step 1: checking the possibility of tooling axis in X, Y & Z direction.

In X – Direction, Maximum part should be producible but side wall not visible clearly.

In Y – Direction, the part looks not a clear dimension so the part should not manufacture under this condition.

In Z- Direction, it's clear to see all the dimension and proper structure of the part.

Tooling Direction: "Z"

Step 2: Create a point on the base surface using the point command option. Using intersection command along the plane "YZ" and draw the line along the "Z" direction on two side walls. Using bisecting line command Draw a Tooling Axis for reference purpose.

Step 3: Using intersection command along the plane "ZX" and draw the line as a Ref. along the "Z" direction on side walls and other line on the centre of the point, make an angle of 3 deg.

Step 4: Using a Bisecting line command to draw a Tooling axis for the surface

Step 5: For creating the draft analysis, first select the "Customize View Parameters" and select the "Material" option

Step 6: Select the Insert > Analysis > Feature Draft Analysis

Step 7: Click the "Compass" icon and drag the compass on the Tooling axis and locking it. Make the draft angle as 3 deg. If the Draft angle is more than 3 deg. It shows a Green colour and 0 deg it shows in Blue colour. If the Draft angle is less than 0 deg its shows in Red colour.

Step 8: Finally our Class A Surface pass the draft analysis test.

Step 9: Same procedure is follow the final part. This means joining of Class A, B Surface & C Surface. Our final output part also clears the Draft analysis.

If we give Draft angle is 3 deg. The sweep area of the class a surface is making blue colour

If we give Draft angle is 1.5 deg. Our final part model clears the draft analysis test completely.

Step 10: Parting Surface

Parting Surface nothing but a surface between core & cavity Block. A parting surface is a surface in the model that you designate to split a work piece, die block, or another volume. A parting surface is made up of a set of features, with the first feature called the base quilt. Any additional features that you create using operations such as trim, merge, and extend are called patches. Before completing a parting surface, you must merge all the patches.

A parting surface must completely intersect the volume and cannot intersect itself. When creating a parting surface, make sure to fill any loops lying on the parting curve.

For creating parting surface first need to extrapolate the Class A

Then trim with the Final product for this case trim with switch bezel. The given output is parting surface with componenet.

If we going to split the extrapolated class A with the Class A Surface, we get the parting surface without component.

Step 11: Core Area

For creating core area, first draw the sketch along Z plane. In the sketch a rectangular block is created to cover the entire switch bezel product and not come outside the Parting surface.

Step 12: Extruded the Rectangular block along the tooling axis direction and trim with Parting surface

Step 13: Then using fill command to cover the top of the Extruded block and using Join command to join the Fill and trim make a close part. This close part is "Cavity". For further more clarity of core movement using translate command and move the cavity block at an height of 50 mm upward.

Step 14: For creating cavity block same set of procedure followed except the trim element. Instead of using parting surface here use Class B surface. Finally we get the cavity block.

Step 15: For parting line creation using intersection command, we are going to intersect the two components. Select the Class A+C surface and Class B Surface to create the intersection and name as Parting line.

Parting line also similar to the parting surface which splits the two mould block (Core & Cavity)

Step 16: using close surface command make the core 7cavity surface as a solid part.

Step 17: draft analysis for core and cavity block

Same procedure for checking draft analysis the Class A & Final Part of switch bezel here also follow the same method.

First change the customized view parameter > material mode. Then using draft analysis option drags the compass and aligned with tooling axis and locks it. Core part will clear the draft analysis.

Same will follow the cavity block also and clears the draft analysis.

View Mode: