Week 9 Challenge

CREATION OF SLIDERS -

a - Relief to the core block  and cavity block- 

We will provide a 2mm relief by using move face tool this relief is to avoid the rubbing of the blocks during the moulding process . 

Similarly we will provide reliefs to the cavity block - 

Below is the cross section view of the blocks with the reliefs , these reliefs will avoid the direct contact of block at 90degree . 

b - Sliders - 

Slider 1 - 

We will create a sketch in th core block on the face where the undercut face is present . the sketch is as shown below. 

Then we will use the split body and select the sketch as input and select the portion we want as slider body . 

We will create a sketch on the same face as earlier and the sketch will have profile for the undercut . we will use the boss extrude and extrude it upto surface and merge it with the slider body . 

We will provide chamfer to the edge so that it matches the undercut . 

We will create a sketch for the hole and we will extrude it upto the face and merge it with the slider body . 

We will use the move face to move the face of slider to 30mm .

We will create a sketch on top face and then extrude it upto the face . this is done to remove the step on the slider . 

We will create another sketch on side face of slider and then we will cut extrude the slider with the sketch . 

Now we will create guide rail for the slider , we will create a sketch on bottom face of slider and then extrude it upto the selected vertex . 

We will use the move face tool and move the face by offseting it such that we will eliminate that face  . 

We will then save this slider body as a separate parasolid file . then we will use combine tool and subtract the slider from the core body . 

we will use the move face tool and move the face for 40mm . 

Now we will have to make clearance space for the bolts so we will create a sketch and then cut extrude the block with this sketch . 

Now we will edit the cavity block , we will insert the imported geometry of slider 1 into the cavity block . 

We will create a sketch on the face and then we will extrude it upto the vertex of the slider , this is done because we have removed the material from the core side so we need add material of same profile to the cavity side for the two block to open and close properly . 

We will use the combine tool and subtract the imported body from the cavity block . 

Now we will start to work on slider 2 , so we will create a plane on the selected face . 

Then we will create a sketch on this plane the sketch will be such that it will accomodate the undercuts . then we will use the split body tool and select the sketch and palne as input and then we will select the required body for the slider . 

We will then create a sketch on the plane and  the sketch will be of the undercut profile , we will use the boss extrude and extrude this sketch upto the surface  and then merge it with the slider body . 

We will save this slider body as separate  parasolid file and then we will use the combine tool and subtract the slider body from the cavity block . 

Now we will create a sketch on top face , the sketch is of rectangle and then we will extrude it upto 61mm . 

Now we will work on the core block to complete the slider 2 profile , we create a reference plane same as we created in the cavity block . 

We will create a sketch on the palne , we will use convert entity and copy the same sketch from the cavity block in this sketch . we will use the split body and select the sketch and plane as input and then we will select the body we need as slider body . 

We will create now create a separte file for slider 2 and then import the two bodies that we had created on the core side and cavity side . we will use the combine and then add the two imported bodies together . 

We will create a sketch on the side face of the slider. we will then cut extrude the part with the sketch . 

we will create sketch for the guide rail on the bottom face of the slider . we will then extrude it upto the vertex . 

We will now edit the necessary change into the core block . we will insert the slider body 2 into core block and we will use combine tool and subtract this body from the core body . 

We will then use the move face tool and move the selected faces for 40mm . 

Now we will have to create a profile for the clearance space for the bolts , so we will create a sketch for the clearance and then we will use the cut extrude tool to cut the block . 

Now we will edit the necessary changes into the cavity block , we will import the slider body 2 into the cavity block . 

Then we will create guide rails in the cavity block as per the slider so we will create the sketch for the guide rail and then we will extrude it upto the vertex of the slider . 

Then we will use the combine tool and subtract the slider body from the cavity block . 

Now we will add bolts to the assembly , we will have to create the respective tapped holes in core side and bolt head clearance in the cavity side . 

We will use the hole command and create tapped holes on the core block for the hardwares . 

Now we will create a bolt head clearance on the cavity body , we will create a sketch of diameter 17mm for the bolt head clearance and then we will use the cut extrude tool and cut the block for 9mm . 

Similarly we will create clearance for the other side as well with depth of 9mm . 

 Creation of inserts  - 

As we can see below in the core block the part has high depth at certain areas that is marked in black , so it can be hard to machine this part for such deep profile which has thickness of 1.5-2mm . so we will make inserts in the core such that we will solve this issue . 

We will first use the move face and give value as 50mm  , this is because the inserts has to be atleast 40mm away from base . 

Now we will create  plane a offset of 20mm from the selected face . 

We will create sketch on top face of the core block , the sketch will be as shown below . 

Then we will use the split body and split the core with the sketch and plane , we will select the respective body athe insert. 

Similarly we will ceate another sketch as shown below . 

We will use the split body tool and select the sketch and plane as input we will select the part we want as insert body . 

So as we can see below in the cross section view , insert 1 and 2 can be manufactured separately and then it can be placed in the core . 

we will use the hole tool and create counterbore hole of m6 for the inserts on the core block . 

We will create sketch of 5.3 diameter for the tapped hole and then we will use  cut extrude and cut the insert bodies for 18mm depth . 

Below  is the cross section view of the block showing the bolt clearances on the inserts and core block . 

We will now create slot for locking mechanism , we will start sketch on face and create profile as shown below .

We will use the cut extrude tool and cut the block with the sketch upto the surface . 

We will create another locking mechanism slot for the other slider . 

We will add fillet of 2mm to the slot . 

We will create a sketch with slot on slider 1 , as we got the distance of slider travel  as  which was 1.51mm so we have to keep it 5mm more which 6.51mm so we will keep it as 8mm .

We will use the cut extrude tool and cut the slider upto the bottom face  .

We will create a similar locking mechanism slot on the slider 2 body . the sketch is as shown belown .

We will use the cut extrude and cut the slider upto the edge . 

Exploded view of assembly  - 

As we can see below , once the part has been cooled off the core will move downwards , along with this the sliders will also move out with respect to their axis .

Now the part will be ejected out of the core  .