ADM80010 DESIGN, MOLDING, MANUFACTURING/NC MILLING OF A PLASTIC TOY BOX COVER ASSIGNMENT SOLUTION

Introduction
Toy box cover is a rectangular arced cover of box and it includes some basic curves and arcs. In this report we will learn the basic sketching and operations to create it. We will also learn the machining, milling and making of mold cavities of the part.

Procedure
1. Start the Creo parametric 3.0
2. Select [File]>New from the menu bar. The dialog box will pop up.
3. Type the part name in text box. Uncheck the “Use default template” box. Press OK.
4. Select “mmns_part_solid” and press OK.
5. You will now see the screen with datum planes.
6. We will first create a sketch and then extrude it to create the model.
7. Select the sketch tool icon from the datum group in the ribbon. A sketch window pops up.
8. Select the plane labelled Front and press Sketch in the pop up window. This will allow you to sketch in the XY plane and extrude in the Z direction.
9. Click on sketch view icon available below the top ribbon in the graphic toolbar.
10. Creo will switch to sketch mode and sketch commands will appear in top ribbon.
11. Now we will draw sketch using sketch toolbar.
12. Select 3 point/ tangent Arc in the sketching group. Draw the four arcs with any dimensions in a rectangular way. The points where the arcs meet draw the 3-point tangent arc to make the fillet like corners.
13. Make sure the drawing is symmetric and closed.

14. Select Sweep in the Model group and Sweep section will appear. By holding Shift key select entire curve path.
15. Click on create or edit sweep section which will take to you sweep section sketch mode.
16. Now select the sketch view and create the sweep section on the plane and click the Green Tick.

17. Now click on the Green Tick on the Sweep dashboard and the sweep section is created.
18. Now create a Plane by clicking on Plane in the Datum Group on the top ribbon. Select the Front plane create an offset till the top surface of the part.
19. Now create the sketch of the surface as shown in the figure below and then fill the section by clicking on Fill icon in the top ribbon. This is done by selecting Sketch 2 and clicking on the Green Tick.

20. Now merge the curves by clicking on Get Data group in the Model Tab. Select Merge/Inheritance and select the curve the that is to be merged and click on the Green Tick.

21. Now create an offset of the sketch by clicking on Sketch 2 model tree and then on the Offset icon from the top ribbon in the Editing group. Give the offset value and Click on the Green Tick to confirm.

22. Now select Sketch icon from the top ribbon then click on the datum plane created as the reference plane. Once the sketching is done Click on the Green Tick to confirm. Now click on the Project icon on the top ribbon. A new tab Projected Curve appears. Select the Surface and give Direction as Along Direction and Click on the Green Tick. The projected curve appears.

23. Now Sketch and project the internal curve following the same previous procedure by selecting the Front Plane and then just selecting the previous curve as reference and giving the required dimensions.

24. After the projected curve is created, select Trim from the Editing group in the top ribbon and click on the curve and give the direction by clicking on the pink arrow and then Click on the Green Tick.

25. Now select the Front plane and sketch the curve with same dimensions as of Sketch 1 on this plane and once it is done click on the Green Tick.

26. Now click on Project from the top ribbon and select Direction as Along Direction and then Click the Green Tick.
27. Now Select Trim option from the Editing group in the top ribbon and click on the curve and give the direction and then click the Green Tick.
28. Now select Curve from the Datum Group in the top ribbon of the tab and Select Curve Through Points from the list. Now select Spline to Connect and then Click on the Green Tick.

29. Repeat the above process to cover all the curves. Once the curves are done Click on Boundary Blend to blend all the curves with the part. Select chain 1 and chain 2 as First Direction and the 12 chains for the Second Direction by default and then Click on the Green Tick.

30. Now select Merge/Inheritance from the Get Data group and then click on the Green Tick to do the merging.

31. Now select Round option from the top ribbon and give the radius and the Click on the Green Tick.

32. Now select the inner curve and click on the Round option, give the radius, and then click on the Green Tick.

33. Now create an arc by selecting the Sketch icon and click OK. Give the reference line as the centerline. Now click on the Revolve option from the top ribbon and click on the Green Tick. Now merge this sketch with the part and using the Merge/Inheritance option from the Get Data group. Now select Round option and then click on the Green Tick by giving the radius. The figure shown below appears.

34. Now select the Thicken option from the Editing group and give the Thickness as 2 and then click on the Green Tick.