Nx Mold Training Material V18 5c5m4q

UNIGRAPHICS

MOLDWIZARD DESIGN PROCESS STUDENT MANUAL September 2002 MT10420 - Unigraphics V18.0.3.2

EDS

Proprietary & Restricted Rights Notices

Copyright Proprietary right of Unigraphics Solutions Inc., its subcontractors, or its suppliers are included in this software, in the data, documentation, or firmware related thereto, and in information disclosed therein. Neither this software, regardless of the form in which it exists, nor such data, information, or firmware may be used or disclosed to others for any purpose except as specifically authorized in writing by Unigraphics Solutions Inc. Recipient by accepting this document or utilizing this software agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other documents or used or disclosed to others for manufacturing or any other purpose except as specifically authorized in writing by Unigraphics Solutions Inc. 2002 Electronic Data Systems Corporation. All rights reserved. Restricted Rights Legend The commercial computer software and related documentation are provided with restricted rights. Use, duplication or disclosure by the U.S. Government is subject to the protections and restrictions as set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation as prescribed in DOD FAR 227-7202-3(a), or for Civilian Agencies, in FAR 27.404(b)(2)(i), and any successor or similar regulation, as applicable. Unigraphics Solutions Inc., 10824 Hope Street, Cypress, CA 90630. Warranties and Liabilities All warranties and limitations thereof given by Unigraphics Solutions Inc. are set forth in the license agreement under which the software and/or documentation were provided. Nothing contained within or implied by the language of this document shall be considered to be a modification of such warranties. The information and the software that are the subject of this document are subject to change without notice and should not be considered commitments by Unigraphics Solutions Inc.. Unigraphics Solutions Inc. assumes no responsibility for any errors that may be contained within this document. The software discussed within this document is furnished under separate license agreement and is subject to use only in accordance with the licensing and conditions contained therein. Trademarks EDS, the EDS logo, UNIGRAPHICS SOLUTIONS, UNIGRAPHICS, GRIP, PARASOLID, UG, UG/..., UG SOLUTIONS, iMAN are trademarks or ed trademarks of Electronic Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the property of their respective owners.

MoldWizard Design Process Student Manual Publication History: Version 16.0.1.3 . . . . . . . . . . . . . . . . . . . . Version 16.0.2.2 . . . . . . . . . . . . . . . . . . . . Version 17.0 . . . . . . . . . . . . . . . . . . . . . . . Version 18.0 . . . . . . . . . . . . . . . . . . . . . . . Unigraphics NX . . . . . . . . . . . . . . . . . . . .

June2000 August 2000 December 2000 October 2001 September 2002

Table of Contents

Table of Contents

Course Overview MoldWizard Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Student Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Student Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lesson Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Workbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . Class Standards for Unigraphics Part Files . . . . . . . . . . . . . Parts Directory Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . Staged Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .

-1 -1 -1 -1 -2 -2 -3 -3 -3 -3 -4 -4 -5 -6 -6

Introduction To MoldWizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What Is MoldWizard? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introductory Lesson Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 1-1: Starting Unigraphics and MoldWizard . . . . . The MoldWizard Design Process . . . . . . . . . . . . . . . . . . . . . . . . Loading A Product and Project Initialization . . . . . . . . . . . . . . Activity 1-2: Beginning a Mold Project . . . . . . . . . . . . . . . . The MoldWizard Assembly Structure . . . . . . . . . . . . . . . . . . . . Define the Mold Coordinate System . . . . . . . . . . . . . . . . . . . . . Assign a Shrinkage Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 1-3: Mold Csys Orientation and Shrinkage . . . . . Define the Work Piece / Mold Insert . . . . . . . . . . . . . . . . . . . . . Work Piece Dimensions Dialog . . . . . . . . . . . . . . . . . . . . . . . Define the Work Piece / Cavity Layout . . . . . . . . . . . . . . . . . . . Activity 1-4: Defining the Work Piece and Layout . . . . . . . MoldWizard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-2 1-2 1-3 1-4 1-6 1-8 1-10 1-14 1-15 1-17 1-18 1-22 1-23 1-24 1-25 1-32 1-33 1-34

EDS All Rights Reserved

MoldWizard Design Process Student Manual

i

Table of Contents

ii

Patching Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extract Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 1-5: Parting, Core, and Cavity Definition . . . . . . . Adding a Moldbase and Standard Parts . . . . . . . . . . . . . . . . . . . Mold Base Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Parts Management . . . . . . . . . . . . . . . . . . . . . . . . . Ejector Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 1-6: Adding a Mold Base and Standard Parts . . . Other MoldWizard Design Process Functions . . . . . . . . . . . . . . Design Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 1-7: Design Changes and Associative Tooling . . .

1-35 1-36 1-37 1-38 1-39 1-57 1-57 1-58 1-59 1-59 1-60 1-80 1-80 1-81

Initializing A Mold Design Project . . . . . . . . . . . . . . . . . . . . . . . . . . Load Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proj Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proj Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cloning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Project Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Product Sub Assembly . . . . . . . . . . . . . . . . . . . . . . Activity 2-1: Changing Project Defaults . . . . . . . . . . . . . . . Mold Csys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shrinkage .......................................... Edit Scale Dialog Options . . . . . . . . . . . . . . . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scale Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scale Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 2-2: Choosing and Setting a Mold Csys . . . . . . . . Instruction Format for Initializing a Project . . . . . . . . . . . . . . . Work Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Piece Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity & Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity Only, Core Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Piece Dimensioning Methods: . . . . . . . . . . . . . . . . . . . Product Maximum Dimensions . . . . . . . . . . . . . . . . . . . . . . . Work Piece Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-2 2-2 2-3 2-4 2-4 2-7 2-8 2-9 2-11 2-15 2-16 2-16 2-16 2-18 2-18 2-18 2-19 2-22 2-23 2-24 2-25 2-25 2-26 2-27 2-27



MoldWizard V18.0.3 Unigraphics V18.0.3.2

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Activity 2-3: Defined Work Piece . . . . . . . . . . . . . . . . .

2-29

Parting Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Design Advisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-1: Product Design Advisor . . . . . . . . . . . . . . . . . . Patch Up Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allow Non-Associative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planar Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-2: Planar Patches . . . . . . . . . . . . . . . . . . . . . . . . . Sheet Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edge Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Existing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Hole Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-3: Surface and Edge Patches . . . . . . . . . . . . . . . . Create Patch Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-4: Patch Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . Split Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Parting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Subtract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Profile Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-5: Solid Patch Compensation in the Tool . . . . . Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 3-6: Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-2 3-3 3-4 3-9 3-9 3-10 3-10 3-10 3-12 3-15 3-15 3-16 3-18 3-19 3-22 3-28 3-28 3-29 3-30 3-30 3-31 3-38 3-38 3-39 3-39 3-39 3-40 3-41 3-56 3-58

Family Molds and Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Family Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Family Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Product and Mold CSYS . . . . . . . . . . . . . . . . . . . . . . . Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Rectangular Layouts . . . . . . . . . . . . . . . . . . . . . .

4-1 4-2 4-3 4-3 4-4 4-5 4-6 4-6



iii

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iv

Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insert Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reposition Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 4-1: Family Mold Project: Toy Shapes . . . . . . . . . Activity 4-2: Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . Removing the only instance of a product . . . . . . . . . . . . . . . . . .

4-9 4-13 4-14 4-14 4-15 4-15 4-15 4-16 4-24 4-29

Core and Cavity Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Search Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eject Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Design Advisor and Auto Patch . . . . . . . . . . . . . . . Traverse Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Split Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Crossover Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Split Faces by Imprinting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Subdivide Isocline Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Add Transition Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 5-1: Parting Curves on a Planar Parting . . . . . . . Activity 5-2: Natural Parting with Isocline Curves . . . . . . Activity 5-3: Selecting Transition Objects . . . . . . . . . . . . . . Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extrude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extrude Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bounded Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-2 5-2 5-3 5-4 5-4 5-4 5-4 5-5 5-6 5-7 5-7 5-8 5-8 5-8 5-9 5-9 5-9 5-10 5-11 5-16 5-25 5-30 5-30 5-30 5-31 5-32 5-32 5-32 5-33




Table of Contents

Swept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Enlarged Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Choosing a Parting Surface Type . . . . . . . . . . . . . . . . . . . . . . 5-39 Edit Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Sew Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Auto Cavity_Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Activity 5-4: Parting Surface Creation . . . . . . . . . . . . . . . . 5-42 Extract Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Core and Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Check Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Check Overlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Create Cavity, Create Core . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Activity 5-5: Core and Cavity Regions . . . . . . . . . . . . . . . . . 5-70 Activity 5-6: Diagnostics in the Extract Regions Dialog . . 5-74 Activity 5-7: Defined Parting . . . . . . . . . . . . . . . . . . . . 5-81 Edit Parting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84 Suppress Parting and Update Parting . . . . . . . . . . . . . . . . . . 5-85 Activity 5-8: Topology Change to Product Model . . . . . . . . 5-86 Compare and Swap Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99 Activity 5-9: Compare and Swap . . . . . . . . . . . . . . . . . . . . . 5-101 Mold Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Base Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Base Index List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit Data Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotate Mold Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expression List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Component Size Lists . . . . . . . . . . . . . . . . . . . . . . . Activity 6-1: Adding A Mold Base . . . . . . . . . . . . . . . . . . . .

6-1 6-2 6-4 6-4 6-5 6-5 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-8

Standard Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Parts Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Part Management . . . . . . . . . . . . . . . . . . . . . . . . . . Ejector Pin Postprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . Slider and Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-2 7-3 7-3 7-3 7-3



v

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Pocket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Standard Part Library Functions . . . . . . . . . . . . . . . . Standard Part Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalog Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Part Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flip Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . True / False / Both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Add/Modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Parameter Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock/Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unlock All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit File / Data Base . . . . . . . . . . . . . . . . . . . . . . . . Remove Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 7-1: Adding Ejector Pins and a Sprue Bushing . Ejector Pin Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Untrim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mold Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fit Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pocket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Target + Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Target Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 7-2: Post Processing and Pockets . . . . . . . . . . . . . . Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi



7-3 7-4 7-5 7-5 7-5 7-5 7-6 7-6 7-6 7-7 7-7 7-7 7-8 7-8 7-9 7-9 7-10 7-11 7-11 7-12 7-12 7-12 7-12 7-15 7-26 7-27 7-27 7-28 7-28 7-28 7-29 7-29 7-29 7-30 7-31 7-32 7-32 7-32 7-33 7-40 7-42


Table of Contents

Solid Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slider and Lifter Sub Assembly Structure . . . . . . . . . . . . . . Orientation of Slides and Lifters . . . . . . . . . . . . . . . . . . . . . . Activity 7-3: Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . .

7-42 7-42 7-43 7-44 7-45

Sub Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Parts as Sub Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . Envelope Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create/Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extrude Edges to Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub-insert Part Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create/Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copy Sub-insert Component . . . . . . . . . . . . . . . . . . . . . . . . Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edit File, Edit Database . . . . . . . . . . . . . . . . . . . . . Activity 8-1: Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-2 8-3 8-4 8-4 8-4 8-4 8-4 8-4 8-5 8-5 8-5 8-5 8-7 8-7 8-7 8-7 8-8 8-8 8-8 8-8 8-8 8-9

Gates and Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gates and Runner Systems Overview . . . . . . . . . . . . . . . . . . . . . Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gate Point Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 9-1: Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Runner Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Define Guide String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sketch Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Curves through Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Add / Remove Curves from Strings . . . . . . . . . . . . . . . . . . . . Projection onto parting faces . . . . . . . . . . . . . . . . . . . . . . . . .

9-1 9-2 9-3 9-5 9-7 9-14 9-14 9-15 9-15 9-16 9-16 9-17



vii

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viii

Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parting Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copy Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Runner Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Runner Design Options . . . . . . . . . . . . . . . . . . . . . . . . Reposition and Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 9-2: Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-17 9-17 9-17 9-18 9-18 9-18 9-19

Cooling Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Component Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 10-1: Cooling Using Standard Parts . . . . . . . . . . . Cooling Channel Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Channel Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balanced and Non-Balanced . . . . . . . . . . . . . . . . . . . . . . . . Define Guide Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Guide Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Guide Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Create/Edit Guide Path Position . . . . . . . . . . . . . . . . . . . . . . Add/Remove UG's Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Show Cooling Channel Relationship . . . . . . . . . . . . . . . . . . . Generate Cooling Channels . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hole Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete Cooling Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 10-2: Schematic Cooling Circuit Design . . . . . . . .

10-1 10-2 10-3 10-5 10-19 10-19 10-19 10-20 10-21 10-21 10-22 10-22 10-23 10-23 10-23 10-23 10-23 10-24 10-24 10-24 10-24 10-24 10-25 10-26

Electrode Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrode Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Part Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 11-1: Electrodes Using Standard Parts . . . . . . . . . Insert Electrode Design Approach . . . . . . . . . . . . . . . . . . . . . . . Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1 11-2 11-3 11-4 11-10 11-11 11-11 11-11 11-11




Table of Contents

Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extrude Edges to Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EWCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrode Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement from Reference Point . . . . . . . . . . . . . . . . . . . Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z-Level Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawing Sheet Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Projection Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity 11-2: Electrodes Using Envelope . . . . . . . . . . . . . .

11-12 11-12 11-12 11-12 11-12 11-13 11-13 11-13 11-14 11-14 11-14 11-15 11-15 11-15 11-16 11-16 11-16 11-16 11-16 11-16 11-17

Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Standard Parts Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 All Parts in Mold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 BOM Field Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 BOM Record Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Activity 12-1: Bill of Materials . . . . . . . . . . . . . . . . . . . . . . 12-6 Mold Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 Balloon tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 Activity 12-2: Drafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 Additional Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity A-1: Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity A-2: Bulb Housing . . . . . . . . . . . . . . . . . . . . . . . . . Activity A-3: Power Tool Casing . . . . . . . . . . . . . . . . . . . . . Activity A-4: Pager Holster . . . . . . . . . . . . . . . . . . . . . . . . . Activity A-5: Snap Lock Tab . . . . . . . . . . . . . . . . . . . . . . . . Activity A-6: Cell Phone Case . . . . . . . . . . . . . . . . . . . . . . . Activity A-7: Phone Jack Case . . . . . . . . . . . . . . . . . . . . . . . Activity A-8: Steam Iron Case . . . . . . . . . . . . . . . . . . . . . . . EDS All Rights Reserved

A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9


ix

Table of Contents

Activity Activity Activity Activity Activity Activity Activity Activity Activity Activity

A-9: Utility Saw Case . . . . . . . . . . . . . . . . . . . . . . . A-10: Sprinkler Housing Cap . . . . . . . . . . . . . . . . A-11: Patch Block with Negative Offset . . . . . . . . A-12: Engine Casting . . . . . . . . . . . . . . . . . . . . . . . A-13: Cast Bracket . . . . . . . . . . . . . . . . . . . . . . . . . A-14: Forged Wrench . . . . . . . . . . . . . . . . . . . . . . . A-15: Game Controller . . . . . . . . . . . . . . . . . . . . . . A-16: Coffee Filter Holder . . . . . . . . . . . . . . . . . . . A-17: Spray Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18: Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . .

A-10 A-11 A-12 A-19 A-20 A-21 A-22 A-23 A-24 A-25

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

x



IN-1


Course Overview

Course Overview MoldWizard Design Process Course Description MoldWizard is a Unigraphics computer application that automates mold design. This course will present MoldWizard in a manner that mimics the Design Process or sequence of tasks commonly used to design a plastic injection mold. During this course, you will create associative two-part molds from Unigraphics solid models.

Intended Audience MoldWizard Design Process is targeted at Unigraphics s who are responsible for injection mold design and development.

Prerequisites Students should be familiar with the basic functions of the Motif Interface, and have taken:

Practical Applications of Unigraphics course

Design Applications Using Unigraphics course

OR

Modeling for Moldmakers course

We highly recommend, but do not require, that the student has:

Mold design experience

Experience with Unigraphics Assemblies, UG/WAVE, and Free Form Modeling



-1

Course Overview

Objectives After successfully completing this course, you should be able to perform the following activities:

Create MoldWizard product assemblies

Create patch up (shut off) geometry

Apply a shrink factor

Create mold tooling inserts

Define core regions within a product model

Create associative core and cavity geometry

Use Mold Base Libraries to choose a standard mold base

Use Standard Part Libraries to select and position common parts, including Insert Pockets, Sub Inserts, Cooling Channels, Gates & Runners, and Electrodes

Create a Bill of Materials

Enter the Drafting Application and begin a mold assembly drawing

Student Responsibilities Experience has shown that you can learn more from this class by:

-2

Participating Enthusiastically!

Sharing Experiences

Giving and Receiving Constructive

Asking Questions

Remaining On Topic"

Listening Attentively and Taking Notes

Being On Time

Having Fun!




Course Overview

Student Manual It is important that you use the Student Manual in the sequence presented. Later lessons will assume you have learned concepts and techniques taught in earlier lessons. If necessary, you can always refer to a previous activity where a method or technique was originally taught.

Lesson Format The general format for lesson content is:

presentation

activity

project

summary

One or more included in most lessons

Activities All activities in this manual will follow a Step and Action Box format. A Step describes what is to be accomplished in that portion of the activity. Steps provide general instructions: Step 1 Define Parting Lines. Indented below each step will be one or more Action Boxes that describe how to accomplish the step. Action boxes provide specific detailed instructions:

Select the Parting Icon.

As your knowledge and skill in the use of MoldWizard increases, you will find that the general Step instructions may be all you need to accomplish a given task. When working through lesson activities, to use the Cue and Status lines for additional cues and information on how to accomplish specific tasks.

Workbook This course also includes a companion Student Workbook. The workbook will provide an opportunity to apply the skills learned through lecture and activities to a real life situation, without specific detailed instructions. The workbook project for this course will be to create mold tooling for a plastic Toy Wagon Assembly.



-3

Course Overview

Classroom System Information Your instructor will provide you with the following: Student :

name: :

Path to mdp_student_home directory:

Instructor: Date:

Class Standards for Unigraphics Part Files MoldWizard Design Process uses standards that are distinct from other Unigraphics Instructor Led Classes. Layer usage, part naming, and considerable automatic geometry creation, all follow standards set by MoldWizard defaults. These standards and defaults will be explained as they are encountered in the course.

-4




Course Overview

Parts Directory Structure Home Directory

The Windows Explorer file structure illustrated is the same for a Unix classroom. Assemblies will be organized within your home directory, typically named moldwizd" or mldwiz00" where 00 will be replaced by a unique number for each student in the class. We use moldwizd" throughout this book to represent any name you have for your home. Projects are grouped by plastic product, in Product Directories.

Product Directories

To find previous work or staged assemblies, begin from your home, open the appropriate product directory, hub2 for example, then open the top level part in that directory, for example mdp_hub_top.



-5

Course Overview

Staged Assemblies Many assemblies are used in this class. Some contain dozens of parts. To maintain a real-life environment, some of the assemblies are used for multiple activities. The class materials contain staged assemblies for every activity except for several very short and simple introductory activities in the next lesson. If for any reason you fall behind the class with a tooling assembly that is used more than one time, please make use of the staged assembly provided.

Spare Parts and Assemblies MoldWizard creates a great number of new part files in tooling assemblies, and it very often modifies assembly structures as you perform normal work. Assemblies and their containing folders (directories) must be read / write in order to permit you to perform the actions required to learn. In a learning situation, this read / write property will occasionally lead to one or more files being modified in a way that was not intended. If an inadvertent action damages a staged assembly, consult your instructor. If the instructor recommends that you replace the assembly with a new one:

-6

Do not hesitate to ask the instructor to help with these steps.

Using operating system functions for whatever system you have, delete every file in the folder where the damaged assembly resides.

Locate a corresponding folder of the same name inside the read only ...Ă/Ămoldwizd / parts folder. This parts folder contains a spare copy of all folders (directories) used in the class, and their contents.

Use any File Copy function on your computer to copy all files from inside the corresponding parts folder into your now-empty directory of the same name.

Begin the activity again.




Introduction To MoldWizard

Introduction To MoldWizard Lesson 1

PURPOSE

OBJECTIVES

This lesson is an overview of the major features of the MoldWizard Design Process. Details of this process will be covered in the remainder of the class.

Upon completion of this lesson, you will be able to:

Start the MoldWizard application and navigate through the student home directory file structure.

Follow the overall MoldWizard Design Process and recognize how the MoldWizard toolbar describes the process.

Observe how MoldWizard automatically updates a mold design to reflect changes made to the original part model.

This lesson contains the following activities: Activity

Page

1-1 1-2 1-3 1-4 1-5 1-6 1-7

1-4 1-10 1-18 1-25 1-39 1-60 1-81

Starting Unigraphics and MoldWizard . . . . . . . . . Beginning a Mold Project . . . . . . . . . . . . . . . . . . . . Mold Csys Orientation and Shrinkage . . . . . . . . . . Defining the Work Piece and Layout . . . . . . . . . . . Parting, Core, and Cavity Definition . . . . . . . . . . . Adding a Mold Base and Standard Parts . . . . . . . Design Changes and Associative Tooling . . . . . . .



1-1

ÏÏÏ ÏÏÏ 1 ÏÏÏ ÏÏÏ



What Is MoldWizard? MoldWizard is a process application for design of plastic injection and other types of molds. MoldWizard's advanced modeling tools for the creation of cavities, cores, slides, lifters and sub inserts are easy to use and provide fast, associative, 3D solid results. MoldWizard automates the difficult and time consuming tasks of mold design. It does so in an increasingly associative way: if the product design is altered, related elements of the mold design will automatically update to reflect the new design. Moldbase and component libraries include parametric moldbase assemblies from a variety of catalogs. Catalog and custom components, including slides and lifters, are accessed via a Standard Parts function that allows s to associatively place components. s may customize or extend MoldWizard libraries to achieve a professional, reusable result without programming knowledge.

Prerequisites To effectively use MoldWizard, the should be familiar with mold design and possess working knowledge of the following Unigraphics applications and tools:

1-2

Feature Modeling

Free Form Modeling

Curves

Layers

Assemblies and the Assembly Navigator

Changing the Display and Work Part

Adding and Creating Components

Creating and Replacing a Reference Set

WAVE Link Geometry





Introductory Lesson Structure In this lesson you will initialize a MoldWizard project and go through the MoldWizard Design Process to create a plastic injection mold that will produce a Business Card Tray.

This lesson is only an introduction to the MoldWizard Design Process. It is intended that you achieve only an understanding of the overall process, and gain insight into how later lessons fit into this process.



1-3




Activity 1-1: Starting Unigraphics and MoldWizard

Your instructor will provide a name and to to your work station, and if necessary point out the procedure to start Unigraphics. Step 1 Log on, Start Unigraphics and enter the MoldWizard application.

If Unigraphics is not already running, please start it now.

Choose Application MoldWizard.

The MoldWizard toolbar displays.

Step 2 Dock" the MoldWizard tool bar.

TIP Some people prefer to dock the toolbar on the left side of the screen. Located there, it doesn't move when you change between Unigraphics applications.

Step 3 Hold the cursor over the various MoldWizard toolbar icons. The functional name of each icon briefly displays as you hold the cursor over it.

1-4





Step 4 Using File Open, examine the directory structure. The file structure on Unix systems is the same as the Windows NT structure pictured below:

Home Directory

Student Project Directories

The parts subdirectory structure is read only." Step 5 Choose Cancel in the Open Part File dialog.

This concludes Activity 1-1.



1-5




The MoldWizard Design Process The MoldWizard Design Process requires a Unigraphics 3D solid part model that is moldable as designed:

We recommend that solid models be modeled in Unigraphics.

If the solid model is not moldable as designed, we recommend that you correct it using standard Unigraphics modeling techniques. Correct models will take full advantage of MoldWizard automation.

The first steps in the diagram below represent the High Level Preparation process of creating and evaluating a part model for moldability. Once the part model is moldable, use MoldWizard Design Functions to determine how the part will be molded. High Level Preparation

MoldWizard Design Functions

Intialize: Create suitable solid model

Use Design Advisor to :

Define: Add the Moldbase

orientation shrinkage work piece

draft parting

Acceptable?

Define Parting Sheets

project name location units

MoldWizard Product Design Advisor

No

Add: ejectors slides, lifters sub inserts

Yes Plan:

1-6

side actions layout sub inserts ejection gating cooling electrodes


No

Acceptable?

Yes Patch Holes


Complete the design with:

gates runners cooling electrodes pockets Bill of Mat'ls Drafting



The MoldWizard toolbar icons represent steps of mold design. They are organized in an order that closely matches the process flow chart shown on the preceding page.

Shrink

Load Product

Parting

Work Piece Family Mold

Standard Parts

Tools

Layout

Electrodes Ejector Pins

A Plate

Mold Trim

Runners

Mold Base

Mold CSYS

Fixed Half

Cooling

Gate

Sliders and Lifters

B Plate

Bill of Material

Pockets

Sub Inserts

Moveable Half

Ejector Plate Return Pins

Mold Drawings

Ejector Plate

s

Retaining Ring & Sprue Bushing Mounting Plate

Cavity Insert (Inside A Plate)

Ejector Pins


Core Insert

Mounting Plate


1-7




Loading A Product and Project Initialization The first step in the mold design process is to Initialize a mold design Project. MoldWizard will automatically generate a mold tooling assembly.

Choose the Load Product icon from the tool bar . . . À

À

1-8

This will open the Open Part File dialog shown below:





Selecting a product part file will open the Project Initialize dialog:

Selecting an existing project “top” file will open this dialog:



1-9




Activity 1-2: Beginning a Mold Project

This activity demonstrates how a product part file is loaded and a mold design project is initialized.

Product:

Business Card Tray

Part File:

mdp_tray

Project Name:

mdp_tray

Unigraphics should be running with the MoldWizard toolbar visible:

1-10





Step 1 Load the Product part file.

Select the Load Product icon.


The file open dialog displays.

Navigate into the tray folder and select mdp_tray.

The part file loads. The Project Initialize dialog displays:

Step 2 Examine the part and review the initial assembly structure. NOTE

Please Do Not dismiss the Project Initialize dialog.

Shade (if necessary) and rotate the part to examine the geometry.

Choose View → Assembly Navigator, or click the icon:

Note that the Assembly Navigator contains a single entry: mdp_tray

Move the Assembly Navigator window to a convenient location, or dock it. Enlarge the Navigator window until it has room to display about 15 lines.



1-11



Step 3 Initialize the Project. In the Project Initialize dialog:

Millimeter as the preferred Unit for this project.

TIP Windows NT systems require a backslash (\) in their

path names, UNIX systems require a forward slash (/).

Choose OK in the Project Initialize dialog. The system generates a mold tooling assembly. When the process is completed the Assembly Navigator displays this structure:

1-12

Expand the assembly tree by selecting the + signs.





Examine the newly generated assembly:

MoldWizard automatically saved an assembly structure named mdp_tray_top.

NOTE

Cancel the Assembly Navigator window.

Do not close the parts. The same parts will be used in the next activity.




1-13




The MoldWizard Assembly Structure How Does it Work? MoldWizard automatically generated an assembly structure by Cloning a blank Seed Assembly that exists within MoldWizard. This Seed Assembly was created using advanced UG Assemblies and WAVE functions that provide the associative interpart relationships that are needed to manage a complex mold assembly. The top" assembly contains all the files necessary for a complete mold tool. The layout" sub assembly can contain multiple instances of one or several products. It's function is to manage the location and orientation of each part in the Mold Base. The prod" or product sub assembly contains files relevant to a particular solid shape that is formed by the mold assembly. MoldWizard identifies the components in the assembly by attributes contained in the part files, rather than by the part file name. This use of attributes allows file name customization, if desired. The seed assembly resides inside the MoldWizard installation directory tree. Appropriate modifications to the seed structure (by a person with the necessary permissions) would be reflected in every future tooling project.

1-14





Define the Mold Coordinate System A Mold Coordinate System (Mold CSYS) must be defined with respect to the part being molded. By convention:

The origin of a mold assembly will lie at the center of the Mold Base

The XC-YC plane of the Mold CSYS will lie where the fixed and moving plates meet, that, at the principal parting plane.

The positive ZC Axis will point in the direction in which the molded part will be ejected from the mold.

Moving Side Fixed Side

Part will be ejected in the direction of the +ZC Axis.



1-15




Procedure

Orient the WCS to match the desired Mold CSYS.

Select the Mold CSYS icon from the MoldWizard tool bar . . . À

À

If necessary, choose the Current WCS option . . . Á

Á

Â

Choose OK . . Â

This dialog may also be used to reposition the Mold CSYS by moving it to the center of the Product Body or the center of a Boundary Face. The Lock buttons allow this repositioning to be done while remaining locked to one of the three principal planes. More information on this dialog will be presented later in the course.

1-16





Assign a Shrinkage Value Mold cavities and cores must be sized to allow for material shrinkage. MoldWizard addresses shrinkage by generating a linked copy of the original product model in a shrink part. This shrink part is used in the process of defining cavity(ies) and core(s). Choosing the Shrinkage icon À will open the Edit Scale dialog:

À

Shrinkage may be assigned using uniform scale in all directions, or with varying shrinkage factors along the X, Y, and Z axis. Once applied, you may edit the shrinkage scale feature at any time by choosing the Shrinkage icon again.



1-17




Activity 1-3: Mold Csys Orientation and Shrinkage

Continue work on your mdp_tray project. Mold CSYS: To orient the part to stand vertical in the mold, the YC axis must be aligned with the length of the part, as shown below. Shrinkage: Uniform, 1.005.

Existing Orientation

Preferred Orientation

XC-YC plane at principal parting

XC-YC plane at principal parting

+ZC is part eject direction

+ZC is part eject direction

YC lies along the narrow dimension

YC lies along the longer dimension

Step 1 Set the Mold Coordinate System.

Choose WCS → Rotate...

that +ZC Axis XC - YC is highlighted.

the angle is set to 90 degrees.

Choose OK.

The YC axis should now align with the length of the part, the XC axis with the narrower width of the part.

1-18





Choose the Mold CSYS icon.

...À

À The Mold CSYS dialog opens.

Choose or that Current WCS is toggled ON . . . Á

Á

Â

Choose OK . . Â

The display reorients to match the new Mold CSYS.

Fit the view.



1-19




Step 2 Assign Shrinkage.

Choose the Shrinkage icon

.. À

À The Edit Scale dialog opens.

1.005

Á

Â When the Edit Scale dialog opens, the Work Part changes. A linked body in the Shrink Part, mdp_tray_shrink, has an existing scale feature. Shrinkage edits the scale feature.

1-20

Enter 1.005 in the Uniform edit window . . . Á

Choose OK . . Â





Step 3 Save your work, without closing parts.

NOTE

Choose File → Save All.

Do not close the parts. The same parts will be used in the next activity. This concludes Activity 1-3.



1-21




Define the Work Piece / Mold Insert The Insert and Work Piece are synonymous.

1-22





Work Piece Dimensions Dialog The Work Piece Dimensions dialog is used to define the type and size of work piece inserts that will be used to form the cavity and core. Work Piece Types: Work Piece type selections include a Standard Block or combinations of independently modeled defined bodies. Work Piece Dimensioning Methods: Two methods for sizing the work piece are offered: Distance Allowance and Reference Point. Distance Allowance Method: The Distance Allowance method references the outer edges of the product envelope À (dashed lines) plus six offsets to define the work piece Á (Solid lines). This method will be used in this introductory lesson.

Á

À

MoldWizard will recommend rounded values for a work piece that will contain the product volume.



1-23




Define the Work Piece / Cavity Layout Mold CSYS addresses only the orientation of the product in a mold cavity. Choose the Layout icon À to define how many cavities the mold will contain and how they will be oriented in the mold.

À

The Layout dialog is used to define both Rectangular and Circular cavity layouts. The mold layout can also be edited using this dialog. Features of this dialog will be covered later in the course.

1-24





Activity 1-4: Defining the Work Piece and Layout

Continue work on the mdp_tray project. This assembly uses a HASCO_E Type 1 (F2M2) mold base. The work piece will be sized to match an available standard plate thickness of this mold base: 27mm below the parting line, and 56mm above the parting line.

56mm

P/L 27mm

Step 1 Define the work piece dimensions.

Choose the Work Piece icon:

This opens the Work Piece Dimensions dialog, and makes mdp_tray_parting the Work Part.



1-25




Edit the Z-Down and Z-Up values to match the intended mold base: Z_Down 27.0 . . À Z_Up

56.0 . . Á

À Á

1-26





Choose OK to accept the remaining defaults.

Fit the view.

TIP Values entered in the Work Piece dialog can be edited

by again choosing the Work Piece icon. More often than not, MoldWizard's recommended insert box size will be adequate for an initial design.

Step 2 Center the work piece/cavity in the mold assembly.

Choose the Layout icon:

The Cavity Layout dialog appears, and the work part changes to mdp_tray_layout.

that a Rectangular, Balanced, 2 Cavity layout is specified . . . ÀÁÂ

Choose Start Layout . . . Ã

À Á

Â

Ã



1-27




Ä

The Cue line reads Select cavity side." The system expects you to indicate the side on which you want the new cavity to be positioned.

Select the vector direction indicator shown above, closest to the rounded side of the tray . . . . Ä

Å

1-28

Choose Auto Center . . . Å





Fit the view.

The layout should appear similar to the illustration above. Step 3 Add tool bodies to define pockets for the workpieces.

Choose Insert Pocket.

À



1-29




Á Â Ã The Insert Pocket dialog allows you to define tool bodies that you can later subtract from mold plates. The resulting void spaces define machined volumes to receive workpieces.

1-30

Set R to 15 . . . Á

Set type to 1 . . . Â

Choose OK . . . Ã





The pocket is automatically sized to contain the two workpiece inserts.

Cancel the Cavity Layout dialog.


NOTE


Do not close the parts. The same parts will be used in the next activity. This concludes Activity 1-4.



1-31




MoldWizard Tools

The Tools icon accesses a variety of MoldWizard functions to:

solid split a work piece for slide actions or sub insert geometry.

solid patch voids within the product model, cavity or core.

sheet patch complex holes or other open surface areas to define shut off geometry within a mold.

These MoldWizard tools are used in close conjunction with Parting Functions to complete complex parting designs. Patching and the role it plays in mold design will become more apparent as we preview Parting Functions. MoldWizard tools will not be required in this introductory lesson.

1-32





Parting Functions Patch and parting operations define the extent or boundary of material belonging to either cavity or core.

Overview of MoldWizard's parting functions:

Parting Lines will identify parting edges or natural parting contours of the product. A sub function can detect and patch simple surface openings with sheet bodies.

Parting Surfaces will generate sheet bodies that extend from perimeter parting edges or contour to the extremities of the work piece.

Extract Regions will interact to identify the cavity and core faces of the product.

Cavity_Core will use the generated sheet bodies and identified cavity and core parting faces to trim cavity and core bodies from the workpiece.

Edit Parting and Swap Model provide means to update parting geometry if the original product model is modified.



1-33




Parting Lines The Parting Lines function is used to identify the perimeter parting edges and/or natural parting contours of the product. Other sub features of this function include:

Split Faces interacts to divide faces that cross the parting.

Transition Objects bridge complex parting sheets.

Choosing the Parting Lines icon will open the dialog below:

1-34





Choosing Auto Search Parting Lines will open the dialog below:

Other sub features of this function include:

Product Design Advisor analyzes the product model for moldability.

Auto Patch detects and patches simple holes in the model.

Patching Operations The parting sheet that will be generated for the tray model À does not for two open slot in the product body Á.

Á

À

Á

These open areas inside the perimeter of the product require Patch Operations that can include:

applying the Auto Patch function, OR

creating patch sheets and bodies explicitly using Tools functions.



1-35




MoldWizard will later use these Patch Sheet bodies, extracted Core and Cavity Regions, and the Parting Surface Sheet body to trim seed blocks for core and cavity. Trim requires a complete and unbroken set of sheet bodies. Without Patch (or shut off) geometry to define where the missing" portion of the product is to be parted, the trim operation that creates the core and cavity would fail.

Parting Surfaces The Parting Surfaces function is used to generate a sheet body that extends from the peripheral parting edges and contours of the product to the extremities of the work piece. Selecting Parting Surfaces will open the Create Parting Surfaces dialog:

From this dialog, parting surfaces can be created and edited.

1-36





Extract Regions In the context of MoldWizard, extracting regions is the process of defining which faces (regions) of the product will be used to form the core side (core regions), and which will be used to form the cavity side of the mold (cavity regions). MoldWizard will identify what it believes to be the correct core and cavity regions. The purpose of the extract regions dialog is to edit (if necessary) and confirm the cavity and core regions identified by MoldWizard. Selecting Extract Regions button will open the Extract Regions dialog:

À Á

Ã

Â

Ã

Key features of the Extract Regions dialog are Face Counts for the total À, cavity Á and core Â faces, and Slide Controls Ã to sequentially display identified Cavity and Core faces, from none to all. The sum of the cavity and core counts should always equal the total face count.



1-37




Cavity and Core Thus far, we discussed:

the Parting Lines function, used to define the parting line, analyze the product for moldability and auto patch holes.

the Parting Surface function, used to create a parting sheet body that extends from the peripheral parting edges of the product to the extremities of the work piece.

the Extract Regions function, used to identify which faces of the product model belong to the cavity, and which belong to the core.

With the completion of the above steps, the system has the information it needs to complete cavity and core bodies. Choosing Core_Cavity will open the Core & Cavity dialog:

Choosing Create Cavity will launch the process that creates the cavity side of the mold insert. Similarly, choosing Create Core will create the core side of the mold insert.

1-38





Activity 1-5: Parting, Core, and Cavity Definition

The parting lies around the bottom perimeter of the tray. The Parting Line function will automatically determine the parting for a product as simple as this one. Given the draft angle detail of the slots (Section AA), shut off" or patch faces must be created on the cavity side of the tray. The Auto Patch function will automatically detect and patch these openings.

Parting Line

A

Draft

A

Stationary

Moving

Cavity

Core

Side

Side

Section A-A Parting Line

Step 1 Define the Parting Line and Patch Regions

Choose the Parting icon:



1-39




The Parting Functions dialog opens.

À

1-40

Á

that Auto Process is OFF (unchecked) . . . À

Choose Parting Lines . . . Á





The Parting Lines dialog opens.

Â

Choose Auto Search Parting Lines . . Â

The Search Parting Lines dialog opens.

Ã



1-41




Choose Apply . . Ã

MoldWizard identifies and highlights the parting lines.

Product Design Advisor and Auto Patch are now available.

Ä

1-42

Choose Auto Patch . . . Ä





The Patch Loops Selection dialog opens. The Cavity Side option is enabled by default . . . Å

Å



1-43




The top edge of both slot openings highlights to indicate two Patch Loops.

Æ Ç

Choose Auto Patch . . . Æ

MoldWizard creates patch sheet bodies to cover both slots.

1-44

Choose Back . . . Ç





È

Choose OK to accept the parting loop previously identified and highlighted by MoldWizard . . . È

The system displays the parting loop. The Parting Lines dialog appears.

É

Choose OK once again, to complete the parting line definition . . . É

The parting loop changes from green to magenta to indicate it has been defined. The Parting Function dialog displays. NOTE

If the Auto Process option had been turned ON in the Parting Functions dialog, the system would automatically advance to the Create Parting Surfaces dialog.



1-45




Step 2 Create Parting Surfaces The parting line was identified and two openings were patched. You will now create a sheet that will later be instrumental in dividing the work piece into its cavity and core components.

À

1-46

Choose Parting Surfaces . . À





The Create Parting Surfaces dialog opens.

Á

Choose Create Parting Surfaces . . Á

The following warning dialog appears:

Â

Choose OK to create a single parting surface . . . Â

The system generates a parting surface and returns to the Parting Functions dialog.



1-47




Ã

Once again, choose Parting Surfaces . . . Ã

If necessary, toggle Show Product Model to OFF . . . Ä

Ä

Fit the view.

You should see the parting sheet, and two patch sheets. A large gap exists in the volume occupied by the product model. To complete the core and cavity definition, you also need to extract two sets of faces, one for the core, and another for the cavity. Each region can fill the void currently displayed.

1-48





Toggle Show Product Model to ON . . . Å

Å

Choose Back to return to the Parting Functions dialog.

Step 3 Extract Cavity and Core Regions. The parting sheet bodies and product model should be displayed and the Parting Functions dialog should be open.

À

Choose Extract Regions . . . À

The Extract Regions dialog opens.



1-49




the face counts in the Extract Regions dialog: Total Faces . . . . . 151 . . Á Cavity Faces . . . . 94 . . . Â Core Faces . . . . . 57 . . . Ã

Á Â

Ä

Ã

Å

1-50

or set the Display Mode to Shaded.

Use the Slider Bars to identify the cavity and core faces as they highlight in the display . . . Ä

Choose OK to accept the system defined core and cavity regions . . . Å





Choosing OK indicates that the faces identified for cavity and core creation appear to be correct. MoldWizard extracts the core and cavity face information and again opens the Parting Functions dialog. Step 4 Create the Cavity and Core Blocks

Set the Display Mode to Wireframe.

Choose Cavity_Core . . . À

À



1-51




The Core & Cavity dialog opens.

Á

Choose Create Cavity . . . Á

A Select Sheets dialog appears. The parting surface, patch sheets, and extracted cavity face region are highlighted.

Â

Choose OK in the Select Sheets dialog.

The system uses the Parting Surface Sheet Body, the two Patch Sheet Bodies and the Extracted Cavity Face Regions of the product model to trim an existing seed Cavity block. The displayed part temporarily changes to the mdp_tray_cavity component. The following dialog is displayed:

NOTE

1-52

Do Not OK or Cancel this dialog until you have examined the newly created cavity!





Examine the cavity: mdp_tray_cavity.

TIP This Cavity Block, mdp_tray_cavity, is suitable for tooling development with UG CAM operations.

Choose OK to return to the Parting Part and the Core & Cavity dialog . . . Ã

Ã



1-53




Choose Create Core . . . Ä

Ä Again, the Select Sheets dialog appears. This time, the parting surface and the extracted core face regions are highlighted. Choose OK in the Select Sheets dialog. The system uses the Parting Surface Sheet Body, the two Patch Sheet Bodies and the Extracted Core Face Regions of the product model to create a Core block.

The displayed part temporarily changes to the mdp_tray_core component, and again the following dialog appears:

1-54

Examine the core.





TIP This Core Block, mdp_tray_core, is suitable for tooling development with UG CAM operations.

Choose OK to return to the Parting Functions dialog . . . Å

Å

Cancel from the Parting Functions dialog.



1-55




Use the Window pull down to change the displayed part to mdp_tray_top.

The cavity/core mold inserts display, with the parting parts suspended inside the mold cavities.


NOTE


Do not close the parts. The same parts will be used in the next activity. This concludes Activity 1-5 .

1-56





Adding a Moldbase and Standard Parts MoldWizard includes spreadsheet driven Moldbase and Standard Part libraries that are used to add a mold base and standard parts to the mold assembly. These libraries may be customized and expanded to fit the needs of the .

Mold Base Management The Moldbase Library includes catalogs from: HASCO, DME, FUTABA (metric only), LKM, and OMNI (inch only). An additional catalog named UNIVERSAL is provided as a template for creating a customized mold base catalog. The mold base catalog list for a metric mold is partially shown below:



1-57




Standard Parts Management The Standard Parts Library includes catalogs from: HASCO, DME, FUTABA (metric only), OMNI (inch only) and YATES (inch only). Also provided are generic catalogs for various Electrode and Insert types. The standard parts catalog list for a metric mold is shown below:

1-58





Ejector Pin and Create Pockets Function. The Activity that follows this discussion will involve the use of two additional functions found on the MoldWizard tool bar: Ejector Pin and Create Pockets.

Ejector Pin Ejector pins are added to the mold assembly from the Standard Parts Management dialog. Once an ejector pin has been added, a separate post processing function, the Ejector Pin function, is used to trim the pin to its proper length and profile.

Create Pockets While the Standard Parts Management dialog is effective at adding parts to the mold assembly, it does not create pockets, holes, and openings that are needed to install these added parts. The Create Pockets function is used to add these needed solid geometry features. The following Activity will add:

A Mold Base

A Locating Ring

An Ejector Pin.

The Ejector Pin will be trimmed to its proper length using the Ejector Pin function. Finally, pockets will be cut into the mold plates and core portion of the mold insert using the Create Pockets function.



1-59




Activity 1-6: Adding a Mold Base and Standard Parts Step 1 Add a mold base.

Use Zoom In/Out to adjust the display to about a quarter of its current size. The display area around the workpiece will soon be occupied by the mold base assembly.

Choose the Mold Base icon to open the Mold Base Management dialog . . À

À

Á

Select HASCO_E from the Catalog pulldown menu . . . Á

The dialog displays sizes and values appropriate for a HASCOE_E Type 1 (F2M2) mold. The dialog also displays a bitmap image of the moldbase.

1-60





Â

Ã

Â

Index size 296x296 is preselected, based on L and W

Ã

L, W, Z up, and Z down are values entered in (or calculated by) Layout



1-61




With your attention directed toward the Graphics Area and the Status line, Choose OK.

MoldWizard generates the components of the selected mold base. This process may take a few minutes. When MoldWizard is finished:

Fit the view.

The figure below shows the mold base with the tray cavity nested between the mold plates.

1-62

Change the display to a Front view. Hint: MB3 Replace_View Front.





Æ Ä Å

Æ

Ä

Plate Component FX_1 (Fixed Half) uses standard plate K20

Å

Plate Component MV_1 (Moving Half) uses standard plate K20

²

Work Piece Z dimensions exceed default K20 plate thickness (22mm) TIP Use the Assembly Navigator to confirm component file names. You will soon see that the base name of components also appears in an editing dialog.

We chose values of 56 and 27 mm for the Z-Up and Z-Down dimensions to match a known standard plate thickness that would accommodate the tray design. As the front view reveals, the thicknesses chosen are not the defaults for the index size needed. You will use a convenient edit function to adjust individual K20 plate thicknesses to appropriate standard sizes.



1-63




Step 2 Edit two K20 plates to suit the work piece.

Choose the Mold Base icon . . . . À

À

Á

1-64

Choose Edit Component . . Á





The Edit Moldbase Components dialog appears:

In the graphics window, select the moving plate indicated in the illustration . . . Â

Â



1-65




The dialog updates to show the standard part file name . . Ã and the catalog designation of the part selected . . . °

Ä

Ã

Change the plate thickness by adjusting the plate_h parameter to 27 mm . . . Å

Å

Choose Apply.

The plate updates.

1-66





Æ

Select the fixed plate shown above . . Æ

Change plate_h to 56 mm.

Choose OK.

The plate updates, and the Mold Base Management dialog reappears.

Choose Cancel.

Choose File Save All.

FRONT view with plates edited.



1-67




Step 3 Add a standard Locating Ring.

Change the display to a TFR-TRI view. Hint: MB3 Replace_View TFR-TRI.

À

1-68

Choose the Standard Parts icon . . . À





The Standard Parts Management dialog opens.

Á Â

NOTE

If necessary, choose catalog HASCO . . . Á

Do NOT choose HASCO_E.

From the HASCO standard parts list, select the K100A (Locating Ring) . . Â

Choose OK.

The Locating Ring is added to the mold assembly. For this particular component, positioning is automatic.

If necessary, choose Cancel in Standard Parts Management.

Using the MB3 menu, set Display Mode to Partially Shaded.

TIP By default, MoldWizard standard parts have the partially shaded attribute. Partial shading makes it easier to examine standard part placement in an otherwise wireframe assembly view.




1-69




Step 4 Add a standard Ejector Pin. In this introductory activity, only one ejector pin will be added.

Once again choose the Standard Parts icon:

Change the Classification field to Ejector Pins . . À

À

The Classification pull down helps you to select from large catalogs by filtering the list to display only one type of part.

Select the Z41 pin from the list . . . . Á

Á

1-70





Change parameter pin_d to 4.5 . . . Â

Â

Choose Apply.

The view is automatically changed to a TOP orientation. The Point Constructor dialog displays.

Choose the Arc/Ellipse/Sphere Center icon . . Ã

Ã



1-71




NOTE

In the graphics window, select an edge of either left arc of the lower slot as shown below . . . Ä

Be careful to select the arc adjacent to the square corner of the tray. The active tray instance might not be the one oriented as shown:

Ä

NOTE

This is only an initial placement. You will adjust the location.

Choose Back in the Point Constructor dialog.

The Standard Part Management dialog reappears. The newly placed pin should still be highlighted. TIP When you specify multiple identical cavities, MoldWizard will use Unigraphics assemblies capability to instance each complete product sub assembly. You need add pins to only one instance of the tray. Other instances will automatically have the same pins.

Step 5 Locate the ejector pin to push against the bottom of the part, between the slot and outside edge.

1-72

Choose the Operation tab from the Standard Part Management dialog . . À





À

Choose Reposition . . Á

Á The reposition dialog appears.

that the dialog is in Transform mode . . . Â

Â Ã

NOTE

In the X input window, type ±1 . . Ã

Use plus or minus, as your part dictates, to move the pin away from the center of the part.



1-73




Press Enter.

If the pin moved in the wrong direction, correct it now.

The pin location updates as soon as you press the Enter key.

In the Y input window, type -5 . . Ä

Ä

Å

Choose OK . . Å

Once again the pin location updates. TIP Pressing Enter works like Apply. The component will move, but the dialog will remain open. When you choose OK, the Reposition dialog will close and the Standard Part Management dialog will reappear.

Choose Cancel.

Using the MB3 menu, choose Orient ViewRight.

Orient View differs from Replace View in that the name of the view and its shading characteristics are retained.

Use Zoom to that the ejector pin is not trimmed.

MoldWizard automatically positioned the base of the pin on the moving ejector plate. The top of the pin will now be trimmed to the correct length.

1-74





Step 6 Trim the Ejector Pin.

Choose the Ejector Pin icon . . . À

À The Eject Pin Post Processing dialog displays.

The options in this dialog will be explained later in the course.

Select the Ejector Pin in the graphics window.

Choose OK to accept the default settings.

The pin is trimmed to match the core insert face.



1-75




Step 7 Create Pockets for the Ejector Pin and Inserts. Typically, pockets are created only after the complete mold design is confirmed. This practice makes editing and repositioning much easier, by minimizing feature updates. Since this is only a demonstration, you will create example pockets now. Create Pocket operations will be used to create ejector holes through two mold plates and the core portion of the work piece insert, and cavities to receive inserts in the applicable plates.

Choose Create Pockets . . . À

À

The Create Pockets dialog displays.

Á

1-76

Choose Standard Part . . Á

Select both instances of the Ejector Pin in the graphics window.

Choose Apply.





Pockets (holes) have now been cut into both mold plates that intersect with the two ejector pins . . . Â

Â

Â

Â

Â

Choose Target + Standard . . . Ã

Ã

The cue reads Select Target Bodies, then Standard Parts."



1-77




Position your cursor over the core insert, and pause (do not move it) until you see the quick pick cursor indicator . . Ä

Ä Å

Select the core insert. Hint: Move the cursor over the numbers in the Quick Pick Tool Å until the Status area reads Solid Body : UM_CORE_BLOCK Click on the corresponding number.

Choose OK.

When you choose OK, target body selection is completed. A Standard Parts selection dialog appears, and the cue reads Select Standard Parts."

Select the ejector pin.

Both core inserts now have a pocket to receive the ejector.

1-78





Step 8 Create Pockets in plates FX_1 and MV_1 for the insert blocks.

Orient View to Trimetric.

Choose the Create Pockets icon.

À

Choose Standard Part . . À

Select the pocket cutting body for the inserts. Hint: Body has dashed yellow lines, looks like this:

Choose OK.

The mold plates now have pockets to receive the inserts.

Choose FileSave All. This concludes Activity 1-6.



1-79




Other MoldWizard Design Process Functions The following design process functions, not included in this introduction, will be covered later in this course:

Gate

Sliders and Lifters

Family Mold

Cooling Mold Trim

Runners Sub Inserts

Electrodes

Bill of Material Mold Drawings

Design Changes Few mold projects are ever completed without a design change. The associativity that links the part model to the mold design is one of the key features of MoldWizard. If a design change is made to the original part model, the mold design will update to reflect the new design. There is a powerful provision to swap the product model for a completely new part. This functionality will assist you greatly if your customer supplies parts that are not modeled in Unigraphics. This functionality will also be covered later in the course. In the following Activity, you will edit the original tray part model using Unigraphics, and the mold design will automatically update to reflect the new design.

1-80





Activity 1-7: Design Changes and Associative Tooling The Product Design Advisor, which you will learn about later, has revealed that the part design does not include needed draft on the two back legs of the part. Step 1 Suppress the parting. TIP Before performing work that may affect the parting, it is good practice to:

Suppress the parting. Perform the work. Update the parting.

Open the Model Navigator.

Choose the Parting icon.

Choose Suppress Parting . . . À

À

In a few moments, the parting features are suppressed.

which features were suppressed by observing the Status column in the Model Navigator, and notice the corresponding check boxes for the suppressed features.

Step 2 Examine the existing mold design.

Use the Window pull down (or if necessary, File Open) to display to open the original part model: mdp_tray.




1-81




Rotate and Zoom the view to observe the design of the front and rear legs.

Draft On The Front Legs

No Draft On The Back Legs

Step 3 Edit the rear leg feature.

Choose Application → Modeling.

Double click over the icon for EXTRUDED(19) . . . À

À

1-82





The Edit Parameters dialog appears.

From the Edit Parameters dialog, choose Feature Parameters . . Á

Á

Another Edit Parameters dialog displays.

In the Taper Angle field, type 1.5 . . . Â

Â

Choose OK in the displayed Edit Parameters dialog.

While observing the status line, choose OK in the original Edit Parameters dialog.



1-83




Status information flashes quickly as features in the tray update. You may be able to see that WAVE linked features in the shrink and parting parts also update.

Choose FileSave All.

Examine the taper that has been added to the mdp_tray part.

The changes you made affect the core region in the parting part. This is why you suppressed the parting before editing. Step 4 Update the parting.


Choose Update Parting . . À

À

In a few moments, all of the parting features are regenerated, and the suppressed status is gone from features in the Model Navigator.

1-84





Dismiss the Model Navigator.

Step 5 the updated mold insert design. The legs are formed in the core side of the mold assembly.

Use the Window pull down to display mdp_tray_core.

In wireframe mode, examine the updated mold insert design and that taper has been added to the core area that forms the rear legs.

Step 6 Save your work. You will have the option to use your assembly again in the lesson on standard parts.

Choose File → Close → Save All and Close . This concludes Activity 1-7.



1-85




SUMMARY

This lesson provided an overview of the MoldWizard Design Process. Greater detail will be provided in later lessons. You have:

Loaded a Product and Initialized a Project.

Defined a Mold Coordinate System.

Assigned a Shrink Factor.

Defined Work Piece Dimensions.

Defined a mold Layout.

Defined Parting lines

Created Patch sheets in shut-off areas.

Created a Parting Sheet.

Identified and extracted core and cavity faces.

Created a Core/Cavity mold insert.

Added and modified a Moldbase.

Selected and Added Standard Parts.

Created Pockets.

This lesson also demonstrated that MoldWizard maintains associativity between a part model and the mold tooling assembly.

1-86




Initializing A Mold Design Project

Initializing A Mold Design Project Lesson 2

PURPOSE

You will practice several initial steps routinely performed when you create Mold Design Projects.

OBJECTIVES


ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ

Change Project Initialize defaults and observe the result.

Discuss the function of each member of the MoldWizard assembly structure.

Analyze a product model to draft and parting considerations.

Explain the capabilities of the Unigraphics Scale function.

Add a defined" work piece to a project.

This section contains the following activities: Activity

Page

2-1 Changing Project Defaults . . . . . . . . . . . . . . . . . . . 2-11 2-2 Choosing and Setting a Mold Csys . . . . . . . . . . . . . 2-19 2-3 Defined Work Piece . . . . . . . . . . . . . . . . . . . . 2-29



2-1


Load Product When you first choose Load Product, the Project Initialize dialog appears:

ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ Unit In your mold_defaults file: !---- Project Initialize Default Units ------------------! !The Project Initialize dialog allows either inch or metric units projects !to be created for inch or metric product models. !The MW_ProjectInitialUnit defines which unit type will be toggled in the !Project Initialize dialog. ! ! =0, No default unit. ! =1, Metric unit as default ! =2, English unit as default ! =3, Plastic part unit as default ! MW_ProjectInitialUnit: 3 TIP

When you Load Product for the first time, the Units of the selected part are displayed in the status window. If you work in mixed units, always observe the status line to check part units as you initialize.

2-2





Set Project Path and Name Browse to a directory where you want your project files to be located . . . À

Proj Path


À Á

Name the subdirectory where the mold project files are to be stored . . . Á MoldWizard will create one level of new directory if a path that ends with a non existent directory is specified. This depends on the having appropriate permissions in the path named. In iMAN, you must manually create a project Folder and place a reference to your product part into the Folder. MoldWizard will place references to all new parts it creates into the same Folder.



2-3


Proj Name


Â

Proj Name defaults to 11 characters. Â The allowed character length a setting that can be edited in the mold_defaults.def file.

Cloning Process When you initialize a MoldWizard design project, MoldWizard uses the Assembly Clone function to copy a MoldWizard seed assembly.

2-4





How Does it Work? Project initialization actually clones two assemblies. The project assembly structure consists of the top" part, and below it var", cool," fill," misc," and layout" parts:

ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ The product assembly structure consists of a prod" part, and below that the original model, cavity", core", shrink", and parting" parts. Multiple product structures may exist within a single project assembly. An Assembly Navigator view of the prod" seed assembly, as it is stored in the MoldWizard structure before a product is added, is illustrated:

MoldWizard will first add the product part to the product structure, representing it by its Empty Reference Set.



2-5


How Does it Work? When a project name and product part name are the same:


When the product name and the product part name differ, as they typically do for Family Molds:

2-6





Field Separators Name Field delimiters are controlled in the mold_defaults file. Do not include separators in names you key in! MW_ProjectNameDelimiter: MW_ProductNameFirstDelimiter: MW_ProductNameSecondDelimiter:

_ (underscore) _ (underscore) _ (underscore)


The prefix mdp_" was added to all part names in this class. This prefix is a departmental standard having nothing to do with MoldWizard. Loading a Product If there is more than one selectable body in the product part, you will be asked to select a solid.

Do NOT use Load Product to load multiple instances of the same product. We accomplish instancing using the Layout function. When you choose Load Product when a MoldWizard assembly is already open, an additional product is added to the layout sub assembly. We discuss this in greater detail in the lesson about Family Molds and Layout.

TIP MoldWizard is designed to work with only one project at a time.

Never attempt to use MoldWizard with more than one top level part open.



2-7


Project Assembly


2-8

TOP - collects and holds all assembly components and related data needed to define a mold design.

VAR - contains standard values that may be referenced by mold bases and standard components. This enables simultaneous customization of all components that refer to these values.

COOL - Cooling Channels will be placed here.

FILL - Gating and Runners will be placed here.

MISC - standard parts that are not specific to an individual product insert, such as locating rings, parting locks, and posts.

LAYOUT - used to position prod" node(s) relative to the moldbase. Multi-cavity or family molds have multiple branches under LAYOUT.





Product Sub Assembly

PROD - files related to an individual product. These include the shrink, cavity, core, and parting parts. Product specific standard parts such as ejector pins, core pins, slides, and lifters may appear in the prod" sub assembly.

Product model - the original part model is added to the prod sub assembly with its name unmodified. It is represented by its Empty Reference Set, thus, it will not be loaded automatically the next time you open your assembly.

TIP A common source of problems for new s occurs when it is

necessary to open the original part. From Directory" is the default Load Method" in the Load Options dialog. Since original parts are frequently not located in the same directory as a tooling project, you might on occasion need to change your Load Method to As Saved," or use File → Open and Filter to the correct directory..

SHRINK - holds a scaled linked copy of the product model.

PARTING - holds the parting sheet body, patch sheet bodies and extracted cavity and core faces used to trim cavity and core blocks.

CAVITY, CORE - cavity and core work pieces, geometry linked to a common seed body in the Parting part.

TRIM - linked bodies in this component are used to trim standard parts using the Mold Trim function.



2-9



TIPS

Keep in mind the advice Save Early, Save Often. Make it a habit to use Save All to be certain you do not lose any modifications to WAVE linked parts in your project assembly. Unigraphics will warn you if you attempt to quit with unsaved parts. Use short project names, and short product names. Unigraphics places a 30 character limit on the size of a part file name, including the four characters .prt".


The Project Name defaults to 11 characters. If you have a lengthy file name convention it might be necessary to copy master files to your project directory, and use abbreviated product names. The use of a copy of the master part need not affect MoldWizard's ability to maintain associativity. As long as a replacement is copied from the same original, updated file, assemblies will continue to recognize it; however, all rules regarding Wave parenting" apply. When you reopen a MoldWizard assembly, that the original part is referenced by it's Empty reference set. Certain functions, such as Edge Patch and Mold Csys, require this part to be open. Open the part before using these functions.

2-10





Activity 2-1: Changing Project Defaults

Step 1 Create a mouse project.

Make sure all parts from previous activities are closed.

Choose Load Product.

Select .../mouse/mdp_mcu.

mdp_mcu is an abbreviation for MoldWizard Design Process Mouse Case Upper.



2-11



NOTE


Change Unit to Millimeter . . . À

The following action is very important!

In the Proj Name window, type mouse . . . Á

the above steps in the dialog shown below, and then choose OK . . . Â

À

Á Â In a few moments MoldWizard finishes cloning the seed assemblies and saves your new structure.

2-12





Step 2 Examine the project structure that was just created.

Open the Assembly Navigator.

Expand nodes mouse_layout and mouse_mdp_mcu_prod and observe the names used.

Question:

How does file naming in your mouse project compare to file naming in your tray assembly?

TIP Toggle the Assembly Navigator off and on with Ctrl-A.

Choose Assemblies Reports List Components.



2-13




Component Report Components of moldwizd\mouse\mouse_top.prt : on 06--03--2002 13:51 Part Name

Ref Set Name Component Name

mouse_cool mouse_fill mouse_layout mouse_mdp_mcu_prod mdp_mcu mouse_mdp_mcu_cavity mouse_mdp_mcu_core mouse_mdp_mcu_parting mouse_mdp_mcu_shrink mouse_mdp_mcu_trim mouse_misc mouse_var

None None None None Empty None None None None None None None

Count Units Directory

MOUSE_COOL 1 MOUSE_FILL 1 MOUSE_LAYOUT 1 MW PROD 1 ORIGINAL PRODUCT 1 MOUSE_MDP_MCU_CAVITY 1 MOUSE_MDP_MCU_CORE 1 MOUSE_MDP_MCU_PARTING 1 MOUSE_MDP_MCU_SHRINK 1 MOUSE_MDP_MCU_TRIM 1 MOUSE_MISC 1 MOUSE_VAR 1

Mm Mm Mm Mm Inch Mm Mm Mm Mm Mm Mm Mm

moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse moldwizd\mouse

All components are positioned as: Absolute

Questions:

What part is represented by its Empty Reference Set?

What part has different Units?

Dismiss the Assembly Navigator and Information windows.

Leave the project assembly open.

The same project is used in the next activity. This concludes activity 2-1.

2-14





Mold Csys Mold Csys transforms a product assembly into mold orientation by transforming that product sub assembly. Mold Csys is product specific. Create family in any convenient orientation, then adjust each member product to match the mold. When the mold contain several products, the active product sub assembly is transformed into the proper mold orientation. NOTE

MoldWizard might remind you to open the original part before editing the Mold Csys.

Current WCS - set the Mold CSYS to match the WCS.

Product Body Center - set the Mold CSYS at the center of the product body.

Boundary Face Center - set the Mold CSYS at the center of a selected face.

Lock Buttons - allow repositioning of the Mold CSYS while remaining locked on one of the three principal planes.



2-15



Shrinkage We have seen that choosing the Shrinkage icon opens the Edit Scale dialog. Once applied, you may edit the shrinkage scale feature at any time by choosing the Shrinkage icon again, whenever the top part is displayed.


Edit Scale Dialog Options Type Uniform - scale uniformly in all directions. Axisymmetric - scale with a specified scale factor (or multiplier), symmetrically about a specified axis. This involves asg one scaling factor along an axis you specify, and another, single scaling factor to be applied to the other two axis directions. General - scale with different factors in all three X, Y, Z directions.

Uniform

General Axisymmetric

2-16





The illustration below shows the effects of the three types of Scale Body feature on simple block and cone shapes.

Before Scale


Uniform Scale Factor 2.0

General Scale Scale Factors: X Axis 2.0 Y Axis 1.0 Z Axis 0.5

Axisymmetric Scale 1.0 along ZC axis, 2.0 Other Directions



2-17


Scale Selection Steps There are four basic selection steps. Availability of each step depends upon the selected scaling Type.


Body - Lets you select one or more solid or sheet bodies for the scale operation. This step is required for all three Type methods. Reference Point - Lets you specify a reference point from which the scale operation is centered. The default reference point is the origin of the current WCS, though you can specify another using the Point Method subfunction. This step is available only with the Uniform and Axisymmetric Types. Reference Axis - Lets you specify a reference axis for the scale operation. Available only with the Axisymmetric Type method. The default is the WCS Z axis. You can change this using the Vector Method subfunction. Reference Csys - Lets you specify a reference coordinate system when using the General Scale method.

Reference Geometry Any geometry you select as an origin or csys reference in the scale dialog becomes associated to the scale feature.

Scale Factors Lets you specify the scaling factors (multipliers) by which the current size is to change. One, two, or three scale factors are required for scale Type Uniform, Axisymmetric, or General, respectively.

2-18





Activity 2-2: Choosing and Setting a Mold Csys Continue to work with your mouse project. Step 1 Determine where the parting should be placed. NOTE

Only if needed, a staged assembly for this activity is in: .../ moldwizd/ mouse_2 /


Procedure to open the staged assembly, if needed:

that no parts are open.

that Application MoldWizard is active.

Open mouse_top in .../moldwizd/mouse_2

Orient View to Front.

The WCS of the upper case, as modeled, is positioned relevant to its product assembly, at the center of a circular opening where the mouse ball protrudes through the lower case.

Make this the main parting plane

The orientation of the WCS is fine for the upper case, but the Z level of the origin is not convenient for molding. If the mold is split at the XC-YC plane of the product, there will be large steps in the parting level between mold plates and part cavites. In our scenario, you decide to locate the WCS in the same plane as the apparently flat section shown at right side of the part in the illustration above. This plane is 12.7 Mm above the current location of the WCS.



2-19


Step 2 Move the WCS to the desired parting.

Choose WCS Origin...

If necessary, Reset the Point Constructor to zero all three numeric input fields.

Key in 12.7 in the ZC input window.


À

Á

Choose OK.

The WCS is relocated to the flat end plane of the case:

2-20

Cancel from the Point Constructor dialog.





Step 3 Set the Mold Coordinate System.


The Mold CSYS dialog opens:


À

that Current WCS is toggled ON . . . . À

Choose OK.

The mouse_mdp_mcu_prod sub assembly is translated 12.7 mm downwards (along ZC-) in the mouse_layout structure. Step 4 Assign a Uniform shrinkage scale factor of 1.005. Step 5 Save your work.

Choose File Close Save All and Close.

Your mouse project will be used again, much later in the class. This concludes activity 2-2.



2-21


Instruction Format for Initializing a Project You will repeat steps very similar to those used with the tray and mouse projects many times as you progress through this class. Reading detailed instructions for many simple, repetitious steps could create danger of overlooking occasional important differences. From this point forward, project initialization steps will be condensed into a short table. Details will be given only as required. Frequently, you will simply accept default values for every input mentioned in such tables.


Path names vary. The variable part of the file path is abbreviated to ..." Examples of initialization instruction format: Step 1 Initialize a tray project: First Part

.../tray/mdp_tray

Units

default (Inch)

Proj Name

default (mdp_tray)

Mold Csys

specified later

Shrinkage Scale Factor

1.005

Step 1 Initialize a mouse project:

NOTE

2-22

First Part

.../mouse/mdp_mcu

Units

Millimeter

Proj Name

mouse

Mold Csys

specified later


1.005

It is acceptable to assign Shrinkage before you set the Mold Csys.





Work Piece




2-23


Work Piece Options NOTE

Previously defined core and cavity inserts may be replaced using the Work Piece function.

Standard Block makes use of geometry linked predefined seed blocks. Cavity Side


Core Side

Defined Inserts: Cavity Only, Core Only, Cavity and Core Defined insert boxes may be used when the size and shape of the insert block is something other than a standard rectangular block, or if the core & cavity require rectangular insert blocks that are different in size. A defined work piece must exist in the parting part, but there are several options for how it is modeled. It may be modeled in the parting part, a geometry linked component , a defined feature or an imported part. NOTE

The parting part contains a linked copy of the shrink body. When the product dimensions are calculated the system will take into whatever shrink has been assigned.

An advantage may be gained by importing a Standard Part as a Work Piece. Sub components may be attached and pocket-cutting bodies may be included with detailed features. These ideas are expanded more fully in the lesson on Standard Parts. The A and B plates of the Moldbase may be geometry linked into the parting part and used as Cavity and Core inserts. In some cases it will be necessary to add material to the cavity and core blocks before trimming the cavity and core. When any of the three insert box type options other than Standard Block are selected, you will be prompted to select a solid body in the parting part to represent the insert box. The body must exist in the parting part. You may create it there, or link it into the parting part.

2-24





Cavity & Core The defined insert body will to be shared by the cavity and core. MoldWizard will use WAVE to copy the body you select. Later it will automatically trim one copy on each side of a parting sheet.


Cavity Side

Core Side

Cavity Only, Core Only A separate defined body may be selected for each tool insert. Select Cavity Only and Core Only (in turn) and identify the defined solids that represent their respective insert box shapes.

Cavity Side

Core Side



2-25


Work Piece Dimensioning Methods: Two methods for sizing the work piece are offered: Distance Allowance and Reference Point. Both refer to the frame of reference used to size the work piece. Distance Allowance Method The Distance Allowance method references the outer edges of the product envelope . . . . À


À

Reference Point Method The Reference Point method references a defined point on the product . . . Á

Á

2-26





Product Maximum Dimensions This field lists the X, Y, Z-Up and Z-Down dimensions of the envelope that contains the shrink part.

Z-Up and Z-Down represents the distance from the parting line to the respective Up & Down extremities of the part.

Work Piece Dimensions

MoldWizard will recommend rounded values for an insert box that will adequately encom the volume of the parting part. By default, it suggests a rounded allowance of approximately one inch around the entire part. Values you enter in the six plus or minus" windows at the left of the dialog are used to calculate the rounded size. Values entered in the four windows at the right of the dialog will be used exactly.



2-27



Workpiece Default Settings The rounding allowance, default method, layer, and layer category name for the work piece are controlled in the mold_defaults file: !---------------Work Piece Offset ---------------!The MW_WorkPieceOffset value specifies the minimum amount that the calculated !workpiece box will be larger (per side) than the product model. MW_WorkPieceOffset: 2.500


!Note: This value is metric and assumes the MW_DefaultsUnit: variable is set to Metric ! !------------------Work Piece Reference Point --------------------------------!The workpiece dialog has two methods for defining the workpiece dimensions !The Distance allowance method is centered on the product body. !The Reference Point method is centered on the absolute csys or a specified point !The variable defines which method will be default in the dialog. ! ! =0, Distance Allowance ! =1, Reference Point ! MW_WorkPieceMethod: 0 ! ... !---------------- Work Piece --------------! MW_WorkPieceLayerName: WorkPiece MW_WorkPieceLayer: 20

NOTE

2-28

Values in the mold_defaults file are initially all metric. A special default specifies the units used in the default file. This permits MoldWizard to control automatic unit conversion as necessary: MW_DefaultsUnit: Metric





Activity 2-3: Defined Work Piece

Step 1 Initialize the hub project using the information provided below:

ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ First Part

.../hub/mdp_hub

Units

default (Inch)

Proj Name

default (mdp_hub)

Mold Csys

default


1.005

Step 2 Create a body suitable for a defined workpiece. In the interest of conserving classroom time, we have supplied construction steps for an appropriate cylindrical body.

Window to mdp_hub_parting and Fit the view.

Make layer 2 the Work Layer.

Choose Application Modeling.

Choose Insert Form Feature Cylinder...

Choose Diameter, Height.



2-29


In the Vector Constructor, choose ZC Axis, then OK.

À


Á

Enter the following parameters, and choose OK.

À Á

Â

2-30





In the Point Constructor, choose Reset to clear previous input, enter ZC -0.75 (notice the negative value) then choose OK.

ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ Á

À Â

Choose Create.



2-31


A cylinder appears, completely encoming the volume of the product model.


Cancel from the Vector Constructor.

Step 3 Identify the cylinder as the work piece. TIP When you enter Modeling, the MoldWizard toolbar may not be displayed. If this is the case, either: Choose Application Õ Gateway... or

Remain in modeling, use the MB3 menu over a toolbar area to activate the MoldWizard toolbar.

Choose the Work Piece icon.

Choose the option Cavity_Core.

The dialog changes to the configuration illustrated below:

À Á Â

2-32





Make layer 2 Selectable.

Select and confirm if necessary the cylindrical body you just created.

Choose OK in the Work Piece Dimensions dialog.

MoldWizard has identified the body you selected as the work piece. Step 4 Define Parting Lines. Removing the work piece cylinder from the display will better illustrate the elements of this step:

Make layer 1 the Work Layer and layer 2 Invisible.


Set/ Auto Process to OFF (unchecked).

Choose Parting Lines.


Choose Auto Search Parting Lines.

The Search Parting Lines dialog opens and the body highlights with a vector arrow pointing up.

Choose Apply.

The external parting loop highlights:



2-33



Step 5 Auto Patch the interior hole.

Choose Auto Patch in the Search Parting Lines dialog.

The Patch Loop Selections dialog opens and the internal parting loop highlights:


Choose Auto Patch again, in the Patch Loops Selection dialog.

A Sheet body is created to patch the interior loop.

Choose Back.

The Search Parting Lines dialog appears.

Choose OK in the Search Parting Lines dialog.

The Parting Lines dialog opens and the exterior parting loop is displayed in green.

Choose OK in the Parting Lines dialog to accept the displayed parting loop.

The Parting Functions dialog opens. The parting loop changes from green to magenta. This color change is a visual cue that the suggested parting loop has been accepted as the parting line. Step 6 Create a parting sheet.

2-34

In the Parting Functions dialog, enable Auto Process. (checked)





Choose Parting Surfaces.

The Create Parting Surfaces dialog opens.

Choose Create Parting Surfaces.

The following Warnings dialog opens:


Choose OK in the Warnings dialog.

The Auto Process feature causes the Extract Regions dialog to open.

Fit the view if the entire parting sheet is not visible.

Step 7 Identify core and cavity faces. Observe the action of Extract Regions on the feature list.



2-35


Open the Model Navigator window.

The most recent feature is CAVITY_EXTRACT_BODY, a copy of CORE_SURF_TRIMMED_SHEET.

In the Extract Regions dialog, choose OK.

The extracted region features appears at the end of the feature list. The Auto Process feature causes the Cavity & Core dialog to open.


Close the Model Navigator window.

Step 8 Create tooling inserts.

In the Core & Cavity dialog, choose Create Cavity.

A Select Sheets dialog opens.


The Cavity Insert is displayed. Notice that the cylindrical work piece was used in place of the default rectangular block.

2-36

Choose OK to continue. The display returns to the parting part, and the Core & Cavity dialog reappears.





In the Core & Cavity dialog, choose Create Core.

A Select Sheets dialog opens.


ÏÏÏ 2 ÏÏÏ ÏÏÏ ÏÏÏ The core insert is displayed.

How Does it Work? When the cylinder was identified as the work piece, MoldWizard updated the WAVE linked bodies to point to the cylinder instead of the default rectangular seed block. To create the cavity, a copy of the cylinder was trimmed using the extracted Cavity Face Regions, the patch sheet, and the parting sheet. To create the core, a copy of the cylinder was trimmed using the extracted Core Face Regions, the patch sheet, and the parting sheet.

Choose OK.

Step 9 Save your work.

Chose File Close Save All and Close.

Later, you will use the hub assembly to create a circular layout.




2-37


SUMMARY


We discussed the activities surrounding a mold project intialization. You had a preview of tooling development process functions that will be explained in detail in the following lessons. In this lesson you:

2-38

Initialized new mold projects.

Reviewed the MoldWizard Assembly Structure.

Set Mold Coordinate Systems.

Reviewed the Scale function used for Shrinkage Factors.

Created a defined work piece and corresponding mold inserts.




Parting Preparation

Parting Preparation Lesson 3

PURPOSE

OBJECTIVES

You will learn methods and procedures used to prepare the Parting Part for its role as WAVE parent of the cavity and core.


Use the Product Design Advisor to analyze a product model.

Apply Solid Patch Up methods that include:

Solid Patch.

Planar Patch.


Learn about and use Sheet Patch Up methods that include:

Surface Patch and Edge Patch.

Patching with Existing Surfaces.

Using Enlarge Surface.

Learn and use solid Split Methods.

Use the Create Patch Block function.

This section contains the following activities. Activity

Page

3-1 3-2 3-3 3-4 3-5 3-6

3-4 3-12 3-22 3-31 3-41 3-58

Product Design Advisor . . . . . . . . . . . . . . . . . . . . . . Planar Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface and Edge Patches . . . . . . . . . . . . . . . . . . . . Patch Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid Patch Compensation in the Tool . . . . . . . . . Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . .



3-1

Parting Preparation

Tools MoldWizard offers a robust set of Tools for Parting Preparation. When a product model has holes or gaps in the natural" parting, the moldmaker must define geometry to represent shut off faces. A shut off is an area where core and cavity steel each other directly in the mold. It is necessary to define geometry in shut off areas for two reasons:


CAM requires geometry to position a cutter on the core or cavity steel. This is true whether the shut off is complex or a simple plane.

Unigraphics requires a contiguous sheet to trim a workpiece to the core or cavity contours.

You used Auto Patch earlier. Auto Patch is an example of MoldWizard's ability to define the geometry of shut off faces. MoldWizard Tools provide several options to cover cases unsuitable for auto patch. The Tools dialog also provides access to the Product Design Advisor, a powerful aid to whether the as designed" parting and draft of a part are suitable for molding. In later lessons you will learn that MoldWizard Tools include other important capabilities.

3-2




Parting Preparation

Product Design Advisor Product Design Advisor offers a wealth of information about how the product incorporates or fails to incorporate draft, undercuts, and holes to be patched. TIP Product Design Advisor can be used to the original part

even before a tooling assembly is initialized. Just open the part, activate the MoldWizard application, and choose Tools. The advisor will be available.

The Product Design Advisor provides face highlighting and if desired, permanent color editing, for faces that:

belong to core or cavity

cross over between the two sides

have little or no draft


Procedure 1. Choose a radio button that applies to faces. 2. Optionally choose a color. 3. Choose Apply.

À Á Â EDS All Rights Reserved


3-3

Parting Preparation

Activity 3-1: Product Design Advisor In this activity we will discover how the Product Design Advisor can be used to evaluate a part even before beginning your mold project. This approach could typically be used to help you estimate the amount of work for the mold, helping you in the quote process. Step 1 Open the part mdp_attachment. NOTE

No MoldWizard functions are required at this step.

Use File → Open.

Filter to .../pda and open mdp_attachment.


Step 2 Activate Product Design Advisor

3-4

From the MoldWizard tool bar choose the Tools icon.




Parting Preparation

From the Tools dialog choose the Product Design Advisor.

MoldWizard evaluates your part. The ejection direction is assumed to be parallel to your current Z axis of your WCS. TIP If a part is not oriented correctly, first move the WCS to the correct position, and only then open the Product Design Advisor.

Step 3 Inspect the part

If necessary, switch your display to Shaded mode.

Choose the Positive Faces option from the Product Design Advisor dialog . . . À

ÏÏÏ ÏÏÏ 3 ÏÏÏ ÏÏÏ À

Rotate your part to review the Cavity side.

Are all faces in the Cavity highlighted? What can you assume about the small faces inside openings?



3-5

Parting Preparation

Choose Negative Faces from the dialog . . . Á

Á

Rotate the part to see the Core side.

Notice that not all of the faces have been highlighted. This indicates that the faces may not have the proper draft applied.


Now choose Small Angle Faces . . . Â

TIP If Small Angle Faces is not available, enter a value in the Draft Angle < field, 3.0 for this part, and choose Apply.

Â In this case we can see there are 44 faces that have a draft angle less than 3 degrees.

3-6




Parting Preparation

Change the Draft Angle to 1.0 degrees . . . Ã

Choose Apply.

Once again choose Small Angle Faces.

Ã

The number of Small Angle Faces has decreased from 44 to 10.

From the Product Design Advisor dialog, make sure the Change Color option is enabled . . . Ä

Choose Pink for the color . . . Å

Choose Apply.

Ä

Å You have now permanently" changed the color of the faces with less than 1 degree draft to Pink.



3-7


Parting Preparation

Choose the Vertical Faces option from the dialog . . Æ

Æ


Change the color to Yellow.

Choose Apply to change the undrafted faces to Yellow.

that Crossover Angle > is set to 5.0.

Now choose the Crossover Faces option.

This indicates that there are 10 faces that cross parting. Later in the class we will address a function that will assist you to subdivide those faces.

Choose Undercut Areas from the dialog. Change the color to Green and choose Apply.

Undercut Areas shows you areas that have negative draft. These areas need to be corrected, or, the customer will have to accept the additional cost of adding a slide or lifter where possible. Shaded images returned to your customer are helpful in communicating the problems with the model. Step 4 Save and Close the part. This concludes Activity 3-1.

3-8




Parting Preparation

Patch Up Overview Many, perhaps most, part designs include a hole or slot on the face of a part that requires a shut off." Where a shut off is used a patch is required. Sheet Patches are used to cover a surface opening and identify from which side the tool steel should emerge. Solid Patches are used fill a void with material that can later be added to the cavity, core, or side action component of the mold to compensate for face and edges removed by the patch. The Parting part initially contains a solid body linked to a parent body in your shrink part, and some seed objects. One of these seed objects is the parent body for the work piece. There are also seed sheets" linked to the core and cavity parts. MoldWizard produces insert tooling by trimming bodies linked to the work piece seed in your parting part. Common parting faces and regions" or sets of faces from the core or cavity areas of the parting part are attached to the seed faces mentioned above. The resulting core and cavity trim sheets are used to trim bodies in your tooling parts. Unigraphics can not use these faces to trim if there are gaps adjacent to parting edges or holes in the interior of the trim sheet. MoldWizard provides several tools to fill in" missing faces. In the following activity you will use Planar Patch, a Solid Patch Up method.

Tolerance

The first control in the Tools dialog is Tolerance. For surface patching, extruding, and splitting tools, this value is used the same way as the modeling tolerance found under Preferences → Modeling. The Tolerance value will be reset to the current modeling tolerance if you exit the Tools dialog then activate it again.



3-9


Parting Preparation

Allow Non-Associative

Enabling the Allow Non-Associative button results in a trade off where file sizes are reduced in exchange for the loss of full associativity with the original part model. There may be times when such a trade off is desired or required due to system limitations. Enabling this button will change the functionality of some MoldWizard processes. Significant changes in functionality will be noted where appropriate. The default setting for this button is OFF in order to maintain full associativity.

Solid Patch Up The Solid Patch Up section of the tools dialog has two functions, Solid Patch, which we will discuss later, and Planar Patch.


Planar Patch

Planar Patch is an extruded solid patch, hence it is found in the Solid Patch Up section of the Tools dialog. Planar Patch is used to create a thin skin over interior holes fully contained in a planar face. Only planar faces with holes are selectable. The system detects all closed loops in the face as holes. You have the opportunity to deselect edge loops that you want to remain open. Be careful here. Loops around raised features and blind holes are detected. The system creates a very thin solid extrusion using the outer boundary to form a patch. Loops that are deselected are used as interior boundaries in the extruded face, thus blind holes will remain open if their edge loop is deselected.

3-10




Parting Preparation

The advantage of Planar Patch is that it works directly on edge loops, requiring almost no extra memory. Surface Patch will make one copy of each surface being patched for each hole. There is a trade off between model size of the parting part and a .0005 inch gap between shut off faces. The thickness of the patch sheet can be edited, but it is not recommended to attempt to use a thickness less than the modeling tolerance. For zero thickness, use a Surface Patch instead.




3-11

Parting Preparation

Activity 3-2: Planar Patches

The mdp_cup3 plastic drinking cup model has several holes. In this activity and the next, you will use Planar Patch, Surface Patch, Edge Patch, and Patch Body to practice the procedure for each function. Step 1 Create a product tooling assembly for mdp_cup3.

If other parts are open, you must close them now.


3-12

First Part

.../cup3/mdp_cup3

Units

default (Inch)

Proj Name

default (mdp_cup3)

Mold Csys

default


1.008




Parting Preparation

Step 2 Create a Planar Patch.

NOTE

Choose the Tools icon:

Choosing Tools changes the current Displayed Part and Work Part to your parting part if the top level, prod, or layout part was displayed, but not if other components were displayed. This intelligence" gives you the convenience of automatically changing the display to the parting part when it is desirable, while permitting you to use the functionality of Tools in other files without hindrance.

Choose Planar Patch.

Notice that only the planar faces at the bottom" of the cup prehighlight as you move the cursor. Only planar faces with holes are selectable. MoldWizard masks faces that are not valid for the current operation, making it easier to select the objects you want.

Select the bottom" planar face and confirm if necessary.

The two holes that through the bottom" of the cup are highlighted. MoldWizard reduces the effort you need to complete the task by detecting loops and selecting them for you. The selection dialog allows you to select or deselect closed loops within the chosen planar face.



3-13


Parting Preparation

Choose OK to accept the two holes the system selected automatically.

How Does it Work? As you create a Planar Patch the Status line reads Creating Extrusion Feature." A Planar Patch is an extrusion of the edge loop of the planar face. This is why planar patch is located under the Solid Patch Up section of the Tools menu.


Cancel the Select Planar Face dialog and the Tools dialog.

From the menu bar choose Application → Modeling.

Choose View → Model Navigator, or choose the icon:

Move the cursor over the second to the last line. This is the EXTRUDED(#) feature that was just created. Double click to edit the feature.

From the dialog choose Feature Parameters.

Notice that the extrusion distance is 0.0005 inches. TIP

You can edit the extrusion distance to whatever value you prefer by editing the feature parameters. It is good practice to maintain a thickness that is greater than the modeling tolerance.

Cancel the Edit Parameters dialog and the Model Navigator window.

Step 3 Save all parts, but do not close!

From the Menu Bar choose File Save All. This concludes activity 3-2.

3-14




Parting Preparation

MoldWizard Tools Dialog (continued) Sheet Patch Up The Sheet Patch Up family of buttons appear at the bottom of the MoldWizard Tools dialog as shown below:

ÏÏÏ ÏÏÏ 3 ÏÏÏ ÏÏÏ Surface Patch Surface Patch is probably the easiest to use patching method. Surface Patch is used for holes fully contained within a single face. Choosing the Surface Patch button opens a Select Face dialog. When a face containing holes is selected, the system searches for closed edge loops (the holes) within the perimeter of the face, highlights each hole, and asks you to select or deselect the highlighted holes for patching. Although Surface Patch and Planar Patch might be considered equally easy to use, Surface Patch will usually add more features to your model than Planar Patch. In Surface Patch, MoldWizard extracts a copy of the underlying face for each selected hole, then trims the copy to the hole edges.



3-15

Parting Preparation

Edge Patch


If holes cross face boundaries, or if a boundary must be created from non contiguous edges, edge patch is useful. With Edge Patch, the is interactively guided to select edges and curves that define the boundary of the patch to be created. Choosing the Edge Patch button will open the following Curve/Edge Selection dialog:

Once the first edge is selected, MoldWizard highlights the Current Path it believes to be the logical path to follow. As the , you will respond to the suggested Current Path using the Curve/Edge Selection dialog shown above.

3-16




Parting Preparation

Accept Choosing the Accept button will accept the Current Path suggested by MoldWizard. Note that choosing Accept is not the same as choosing OK. Accept only confirms the curves in the current path , allowing the system to focus on finding the next curve. Next Path The Next Path button, will as the name implies, suggest and alternate branching path from two or more possibilities. Back Traverse This option will appear when a second edge or curve is selected. Choosing this button allows you to go back and correct an earlier selected branch. Close Loop This button will create a connecting line between the open end point of the first edge selected and the open end point of the current path edge or curve. Exit Loop This button indicates that you have finished your selection and signals MoldWizard to begin generating a patch based on the geometry selected. It is not necessary to accept edges offered by the system. All curves and edges are selectable. In some cases, where curves or edges from multiple bodies have been chosen, the system may not determine a current path. If this occurs just select the next edge you want. If you choose an edge that is not contiguous with the current patch, MoldWizard will offer the Bridge Gap dialog. Bridge Gap When non contiguous edges or curves are selected, MoldWizard will display the following dialog:

If you click on Yes, MoldWizard will bridge the gap with a line. MoldWizard will enlarge and trim the created patch surfaces to the boundary.



3-17


Parting Preparation

Existing Surface


MoldWizard recognizes that there may be times when the automated features of Sheet Patch Up are not suited for a particular application. One instance where this is likely to occur is when you are working with imported file formats such as IGES, Parasolid, etc. When the conventional methods of surface patching are not successful, you may create the surface patch manually using Free Form features or other Unigraphics functions. Once created, you can return to the Tools dialog and choose Existing Surface, where you will then be prompted to select the surface you created (or another existing surface you may wish to use) for Sheet Patch Up. The system will make copies of the sheet for both core and cavity trim.

3-18




Parting Preparation

Auto Hole Patch Auto Hole Patch can automatically patch up all through holes in the product using a surface based patch method. When Auto Patch is selected, the Patch Loops Selection dialog will open and detected open loops will highlight.

1. Select a Patch Method. 2. Select Auto Patch to create the patch surface.

Patch Method Patch Method refers to where the patch will be applied: the Cavity Side or the Core Side. When multiple loops requiring different patch methods are detected; or, if some of the detected loops do not require patching, the One by One Method should be employed to address each loop individually. Selecting the One by One method will open the following dialog:



3-19


Parting Preparation

The One by One method will cause hole edge loops to highlight individually. Three options are then provided for each highlighted loop: Patching: This option will cause the system to analyze the detected hole for draft and other attributes, then apply a patch to the side it deems appropriate. Skip: This option will simply skip the highlighted loop and move on to highlight the next loop. A patch will not be applied to the skipped loop. Extract: This option will extract curves matching the highlighted loop. Extracted curves of this type can then be used with other modeling functions to explicitly create a custom patch body or sheet. Regardless of the Patch Method specified, MoldWizard will analyze an identified hole for draft and other attributes and intuitively determine one of two things:


The side MoldWizard deems to be appropriate for patch placement, based on analysis to prevent undercuts. OR

Either side could be appropriate for patch placement.

If the specified patch method conflicts with what MoldWizard has determined to be the correct placement face, the specified method will be ignored. If MoldWizard determines that either side could be patched, the specified method will be honored.

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Parting Preparation

In this example, MoldWizard will place the patch on the core side regardless of the Patch Method specified. To do otherwise would result in an undercut or mold lock condition.

CAVITY SIDE

CORE SIDE

Patch Placement

Working Around MoldWizard's Intuition A wide variety tools are made available for creating patch surfaces and patch bodies. In cases where an undercut is indeed an intended design feature, patch surfaces and bodies can be created using patching tools other than Auto Patch.



3-21


Parting Preparation

Activity 3-3: Surface and Edge Patches

Continue to work with your mdp_cup3 project. NOTE

In a few minutes you will retrieve the parting part as it is now. If you did not save at the end of the last activity, Save All now.

NOTE

Please do not save after this, until instructed to do so!

Step 1 Only if needed, a staged assembly for this activity is in: .../ moldwizd/ cup3_2 /


Procedure to open the staged assembly, if needed:



Open mdp_cup3_top in .../moldwizd/cup3_2

Step 2 Patch holes in the conical face. The following two steps are done to learn how the Patch Surface feature works. Don't worry about the geometry configuration. We will take care of some problems in a few minutes.

If necessary, choose Tools:

Choose Surface Patch.

As you move the cursor over the graphics window, observe that only faces with interior holes prehighlight. The planar face with holes that you did not patch earlier is also selectable. Unlike Planar Patch, Surface Patch creates sheet bodies.

3-22




Parting Preparation

Select and confirm the outer face of the cup".

A Select Holes dialog appears. Detected holes are pre-selected.

Choose OK in the Select Holes dialog.

In a second or two, patch sheets are created.

Cancel the Select Face dialog and the Tools dialog.

How Does it Work? The system extracts a sheet body, the same as you would obtain using the tool Enlarge Surface. This sheet is the parent for one or more patch sheets, one for each hole being patched.

Creating a patch skin over the holes is sufficient to allow MoldWizard to calculate core and cavity regions; however, simply patching the holes with the easiest method may not meet engineering design intent for useful tooling. The holes through the conical faces are patched, but a volume of material will be left in the core area that will not permit removal of the plastic. This part requires sliders" or draws", movable pieces of the mold that form the holes during injection and are withdrawn before the product is ejected. In the following steps you will revert to the previously saved parting body, and patch the two conical faces of the cup with solid bodies that can be incorporated into slides.



3-23


Parting Preparation

Step 3 Reopen your parting part.

Choose File → Close → Reopen Selected Parts.

À


Á

Â

3-24

Select your mdp_cup3_parting part from the list box.

Enable Force reopen if modified.

Choose OK.

Dismiss the reopen information window.




Parting Preparation

Step 4 Patch the hole through multiple faces using Edge Patch.

Zoom in on the hole ing through the cone and bottom faces, as shown in the figure below:

À

Reopen the Tools dialog and choose Edge Patch.

Select edge À as shown in the figure.

Use the controls in the Curve/Edge Selection dialog to guide the system to selecting the edges shown in the figure until the loop is closed.

When the loop is closed, the system displays an Add or remove faces dialog. The status line reads Found 3 faces to patch up."

Choose OK to accept the highlighted faces.

Cancel the Tools dialog.

Note: Shading the part will display the patch just created.



3-25


Parting Preparation

How Does it Work? Internally, MoldWizard creates a linked face and a scale feature for every one of the selected faces. The linked faces point to the original product model, hence the same scale used for the shrink part is applied to each linked face. These new features are bundled together in a feature set named patch_set. The original part must be open for this process to work properly. Be careful ing edge patch in an assembly that was reopened from the disk. The original part is represented by its empty reference set, and will not be opened. Creating linked bodies and updating of the original model with link information takes measurable time. In this part, the time is negligible; however, in larger parts the delay can be significant. A default is provided to set a maximum number of features in the original part. Beyond this maximum, edge patch will use an alternative curve mesh approach for Edge Patch:


MW_ToolsPatchFeatureNum: 150 The linked faces are sewn into a single sheet. The sewn sheet is then trimmed to the edge loop selected for the patch. If the patch can not succeed by the method described above, and the loop consists of a single curve, MoldWizard might create a PATCH_THRU_CURVE_MESH feature. This behavior may be turned on or off in the mold_defaults file by: MW_PartingMeshSurf Sometimes a PATCH_THRU_CURVE_MESH will be perfectly acceptable. At other times, you may wish to model a new sheet and use EXISTING SURFACE to complete the patch. Step 5 Save your work, but do not close any parts.

3-26





Parting Preparation

NOTE

Warning Message The original product part is modified" by extracting sheets. If that part is read only, you will receive a message when you save all parts, informing you that although the overall operation was successful, one part failed to save. It is not good practice to ignore warnings and error messages unless you are confident that you understand the situation and can deal with the consequences. The set up instructions for your classroom request that all your parts are read / write; however, work situations will arise when the original part is read only. At many companies, original parts are read only to prevent accidental changes by any one . It does not matter if modified original parts are not saved. You can dismiss and ignore warnings about original product models only.


If necessary, dismiss the above warning by choosing OK.

NOTE

If your classroom is set up properly, you will not see the above warning. If the warning does appear, please inform your instructor.

NOTE

You will continue to use this project in the next activity. This concludes Activity 3-3.



3-27

Parting Preparation

MoldWizard Tools Dialog (continued) Create Patch Block The Create Patch Block section of the tools dialog contains only one button, used to create an associative body that can be used as a solid patch, described later.


Create Box A patch block is a good way to complete a parting shape for a local area that is not suitable for surface patch or edge patch, two methods that are discussed in the following paragraphs. The patch block is also a good way to create geometry for slides. Creating a patch block accomplishes the first two steps of a five step process:

Define a suitable allowance for trim or draft.

Select faces to define the block volume The system will build a bounding box" around the faces you select, leaving the Allowance amount as extra stock" around the minimum box that could contain the surfaces.

3-28




Parting Preparation

Trim the patch block to fit the volume you wish to patch.

Apply the patch using the solid patch option on the Tools menu. This step fills in openings between the core and cavity regions, but in most cases, other faces are also removed.

Later, locate an automatically linked copy of the patch solid and use a boolean operation to complete your tooling. This action is necessary to replace product faces and edges that were removed from the tooling by the previous step.

The system creates a solid block within a volume you define by selecting (roughly) bounding geometry. The Allowance value determines how much larger the block will extend beyond the volume you select. The tool dialog provides several methods to shape this block to make a plug" for holes. A toggle controls whether non associative methods are available. As noted previously, non-associative methods gain an advantage in disk and RAM Memory requirements by sacrificing associative update capability. The initial setting of the toggle is controlled in the mold_defaults file. The block must be trimmed, applied, and later compensated as outlined above. An activity will clarify the use of patch blocks. Surface Split Surface Split, found in the Tools dialog under Split Method, may be used to shape a patch body to match part contours. In associative mode a combination of Extract Body and Trim is used; in non-associative mode Split is used. If the selected face is planar a datum is created and used to trim. If the face is non-planar a copy is extracted, and the copy is used to trim.



3-29


Parting Preparation

When a copy is extracted it is initially only a small amount larger than the original face. If the system detects that the enlarged face is not big enough to perform trim, a second dialog (shown above) is presented offering additional enlargement tangent to the edge of the original face, up to 900%. If this is still not large enough to successfully trim, you can use the Enlarge Surface function (described later) and split or trim manually.

Solid Patch Up We have already examined Planar Patch and previewed Solid Patch. Solid Patch is often used when geometry is too complex to trim, or when trimming functions are simply too time consuming.

ÏÏÏ ÏÏÏ 3 ÏÏÏ ÏÏÏ Solid Patch The system guides you to select a target solid (your parting body) and a tool solid. We refer to the tool body as a patch block, typically but not necessarily created using Create Box. Unlike patch sheets, which have no volume, a solid patch changes the shape of the parting body and one of the mold regions. After parting, core, and cavity creation a copy of the same solid patch material must be united or subtracted to compensate for the effect of the patch body. The system provides a linked copy of patch blocks. It is necessary to manually" perform the required boolean operation in the appropriate part. When using solid patch, be very careful not to create internal empty volumes inside the part. The geometry of internal empty volumes will not appear in any piece of tooling.

3-30




Parting Preparation

Activity 3-4: Patch Blocks

Continue to use your mdp_cup3_parting part. Step 1 Only if needed, a staged assembly for this activity is in: .../ moldwizd/ cup3_3 / Procedure to open the staged assembly, if needed:



Open mdp_cup3_top in .../moldwizd/cup3_3


Step 2 Create a patch block for the small circular opening in the conical wall of the cup.

If necessary, choose Tools.

Choose Create Box.

In the Create Box dialog: Type: Allowance . . . . . . . . . . 0.125



3-31

Parting Preparation

Select and confirm the cylindrical face of the small hole.

OK is not active until you have selected at least one face.


Choose OK to indicate you are finished selecting faces.

A block is created encoming the volume of the face you selected. Step 3 Trim the block to exactly fill the hole.

Choose Surface Split from the Tools dialog.

Select and confirm the new block.

The Cue reads Select a surface to split the solid."

3-32

Select the same cylindrical face as you did in the previous step where you defined the block.




Parting Preparation

N

If the Normal Indicator (N) points away from the volume you want to keep (inside the hole), choose Trim or OK.

If the indicator arrow were pointing the wrong way you would choose Flip Trim". The cue line prompts again for a surface to split the solid.

Select and confirm the outer conical face of the cup.

Again, the indicator should be pointing in the correct direction.

Choose OK to trim the side indicated.

Select and confirm the inner conical face of the cup.

This time the indicator should be pointing outward, the wrong direction.

Choose Flip Trim to remove extra material inside the cup.

Choose Cancel to exit from the Surface Split operation. Note: Shading the view will make the solid visible.

How Does it Work? Create Box creates a UDO ( defined object) and a sweep feature. s of earlier releases of MoldWizard would have observed a single block feature. The UDO and sweep combination provides full associativity between the patch block and the faces selected.



3-33


Parting Preparation

Surface Split trim sheets are created in Layer 255, or whatever is designated as MW_HideObjectLayer in the mold_defaults file. TIP Avoid making MW_HideObjectLayer visible or

selectable. MoldWizard places certain objects that are displayed temporarily into the layer designated by the MW_HideObjectLayer setting.

Step 4 Patch the remaining rectangular opening.

In the MoldWizard Tools dialog choose Create Box.

TIP When you use Create Box:


3-34


Be careful to pick enough faces to define the volume you want. Two faces are sometimes enough; occasionally only one is required.

Be careful to pick any faces for which associative update is desirable!

The system will create a block oriented to the ACS that encloses the faces you select.

Extra" volume is determined by the Tolerance setting in the Tools dialog.



Parting Preparation

Select and confirm the upper and lower faces, as shown below, in the upper rectangular opening.

In the current example, the side faces do not sufficiently define the volume required, due to the curvature of the cup wall.

Á

À

NOTE

Again type Allowance . . . . . . . 0.125

Choose OK.

Choose Surface Split.

Select and confirm the new block as the solid to be split.

One by one, select and accept six trim sheets:

the four sides of the opening

the inner and outer faces of the cup.


to choose Flip Trim where necessary!

Choose Cancel when the block is fully trimmed.



3-35

Parting Preparation

Step 5 Create Solid Patches.

Choose Solid Patch in the MoldWizard Tools dialog.

Select the cup body as the target solid.

Select first one, then the other patch block as a tool solid.

Choose OK after you select both patch blocks.

Cancel the MoldWizard Tools dialog.

How Does it Work? As you select each tool solid, the system:


moves the body into MW_PartingPatchBodyLayer (25)

creates an extract body

unites the extracted body to the target solid

If the product model changes, trim sheets update the original body. Then, extracted bodies update. The extracted bodies are united to the parting body, so it too updates. It is up to you, the tool designer, to use an appropriate Boolean operation to compensate for geometry removed from the product model by Solid Patch. At a later step in the process the MoldWizard system will place a WAVE linked body" for each tool solid into the MW_PartingPatchBodyLayer in both core and cavity parts. This automatic linking makes it easy for you to compensate the material volume associatively. Typically, you will unite the copies to a tooling body in your choice of the core or cavity part.

3-36




Parting Preparation


NOTE

From the Menu Bar choose File Close Save All and Close.

If necessary, dismiss the above warning by choosing Close Part.

If your classroom is set up properly, you will not see the above warning. If the warning does appear, please inform your instructor. This concludes Activity 3-4.



3-37


Parting Preparation

MoldWizard Tools Dialog (continued) Split Method The Split Method section of the dialog contains several tools, aside from Surface Split, which we covered earlier, to divide or trim a body. As with other operations, full associativity is the default.

ÏÏÏ ÏÏÏ 3 ÏÏÏ ÏÏÏ Solid Parting In cases where it is difficult or cumbersome to use surface trim parting methods, Solid Parting is used. You must first define work piece dimensions using the Work Piece icon on the MoldWizard tool bar. The shrinkage part will be subtracted from a linked copy of the work piece. Choose a Split Method to divide the body into core and cavity sections. Another immediate effect of choosing Solid Parting is to remove core and cavity components from the product assembly.

3-38




Parting Preparation

Subtract Frequently the contours of the part require many trim operations to shape a patch block. At times, the contours are too complex for trim to be an effective option. In such cases, one Subtract will produce the correct shape. The MoldWizard Subtract function is similar to the UG Subtract function, except that the tool solid is retained after the operation. The system asks you to pick a target body, usually your patch block, and a tool, usually the shrink model. In associative mode, the system extracts a copy of the tool solid and subtracts the copy from the tool. In non-associative mode, the system creates interference bodies between the target and tool, and subtracts the result from the target. Solid Split Solid Split is very useful to break out" a section of the part that will be a moving piece in the tooling. It creates the interference solid(s) between a target and a tool body, and subtracts the tool volume from the target solid. In associative mode the operation is performed with extracted bodies. In non-associative mode every resulting body will be an unparameterized feature. Split Split asks the to select a target solid and a tool sheet or datum. In associative mode the system uses extract body to make a second copy of a target solid. The tool sheet or datum is then used to trim both bodies, each on opposite sides of the trim object. The tools sheet and both trimmed bodies remain and are associative. In non-associative mode the splitting face is used to divide the target body into two unparameterized features. The splitting face is removed from the model in this mode. A datum plane can be used to split a solid only in associative mode.



3-39


Parting Preparation

Profile Split A target body is split using an extruded closed profile. You will be prompted to select curves or edges to extrude. Choices are added to the options in the dialog with the first and second picks. By the third pick, the dialog appears as shown:

The vector subfunction is presented to determine the extrude direction.


Finally, a dialog is presented to set extrude distances:

3-40




Parting Preparation

Activity 3-5: Solid Patch Compensation in the Tool

This part:

demonstrates the Subtract tool

previews the procedure to unite a linked patch body in core or cavity to compensate for geometry removed by Solid Patch

Step 1 Create a project for mdp_cap.


First Part

.../cap/mdp_cap

Units

default (Inch)

Proj Name

default (mdp_cap)

Mold Csys

default


1.008

Work Piece

default

Layout

Auto Center



3-41

Parting Preparation

Step 2 Prepare the part for tooling design. This part has 12 windows that must be patched before we can trim core and cavity inserts. The window edges are shared between multiple faces, therefore the face cannot be patched with Surface Patch. Auto Patch works, using edge patches, but it tedious to repeat the face confirmation process twelve times. In this case, Solid Patch is an efficient method to use.


Choose Tools.

Choose Create Box.

Use the default value for Allowance. (Ignore the Allowance text input window.)

Select, and confirm if necessary:

the inner face containing the window openings . . . À

the small inner face nearest the top of the cap . . . . Á

Á

À

3-42




Parting Preparation

Choose OK to end selection.

A block is created surrounding the material volume defined by the faces you selected.

The patch block can be trimmed in one or two areas, but there are several concentric faces with opposing directions. With multiple faces and complex geometry it is a lot faster to use a Boolean subtract to shape the patch body using Subtract in the Split Method section of the Tools dialog. The current topology presents a problem. A Subtract at this stage would divide the patch block into more than one piece. When Subtract divides a body into multiple pieces, it causes all parameters to be removed. In our scenario, we specify full associativity, thus, we need an approach that retains parameters. We can avoid trouble by trimming the rectangular patch body to the largest inside diameter of the part before we subtract.



3-43


Parting Preparation

Step 3 Trim the patch block to the interior shape of the pen cap.


Select and confirm the block you just created as the solid to be split.

Remove the outer material by selecting the inner face containing the windows. (The same face you used to define the patch block.)

Choose Trim.

The enlarge sheet dialog appears.

Do NOT change U.

Expand in the V direction to approximately 400%, until the cone extends past both ends of the block.


N

3-44

Choose OK to accept the UV values and trim the patch body.

Cancel to return to the Tools dialog.




Parting Preparation

Step 4 Use Subtract to complete the patch body.

NOTE

From Tools, in the Split Method section, choose Subtract.

The order of selection is very important. Watch the Cue!

Select and confirm the smaller, green patch body as target.

Choose the larger, cyan parting body as tool.




3-45

Parting Preparation

Step 5 Use the patch body to create shut off faces in the windows.

Choose Solid Patch.

Select the larger, outer pen cap body as target solid, and the smaller interior patch body as tool.

Choose OK or Cancel to dismiss the selection dialog.

The unite operation performed by Solid Patch removes several faces from the core region of the parting part. These removed faces will not appear in the core tooling when it is initially created. You must plan to compensate. MoldWizard will make linked copies of the original patch body, now in layer 25, in the core and cavity parts. You can use this knowledge to complete your plan to replace the removed faces. The following steps give you a preview of the actions necessary to replace the missing faces in the core workpiece. This will help you to fully understand what you accomplish by uniting a patch body.


Step 6 Create a Parting Curve and Face.


Enable the Auto Process toggle.

Choose Parting Lines.


À

3-46

Choose Apply in the Search Parting Lines dialog . . À




Parting Preparation

MoldWizard identifies the correct parting loop . . . Á

Á Once the parting loop has been identified, the Product Design Advisor becomes available. Auto Patch remains grayed out, an indication that Solid Patch successfully removed all holes from the part.

Â

Choose Product Design Advisor . . Â



3-47


Parting Preparation

Product Design Advisor tells you at a glance that there are no vertical faces, one potential undercut area, and 65 Small Angle Faces with a Draft Angle less than 3°.


Choose the Undercut Areas radio button to what the system has found.

The bottom face of the patch body, remaining after Solid Patch, is highlighted. In wireframe mode, you might be able to discover a reason for such a face being highlighted, perhaps a small gap caused by tolerance issues. There will be no problem with this part; however, it shows the value of the Product Design Advisor as a diagnostic tool.

Choose the Small Angle Faces radio button to highlight faces with draft angles less than the value in the Draft Angle < window.

Almost every face on the Cavity side highlights.

3-48




Parting Preparation

We know there are no Vertical Faces, because that radio button remains grayed. We can use the Product Design Advisor to quickly investigate the minimum draft on the product.

In the Draft Angle < window, enter: 1.000

Choose Apply.

À

Type a value

Interpret the result


Â

Á Apply the change

Small Angle Faces now displays 25 faces, 24 faces between the ribs" and one small conical face at the top of the part.

Change the Draft Angle < value to 0.5, Apply, then choose Small Angle Faces once again.



3-49

Parting Preparation

The small face at the top is no longer highlighted. It is drafted at least half a degree.

Change Draft Angle < to 0.49

Small Angle Faces are no longer found. The part has approximately 0.5° draft, within .01 degrees!

NOTE


Choose OK to exit the Product Design Advisor.

Choose OK in the Search Parting Lines dialog to accept the previously identified parting loop. (It is no longer highlighted.)

The parting curve (only one arc in this case) is displayed, colored green. The green color indicates that while geometry has been chosen, the process is still incomplete. It is important not to dismiss the Parting Lines dialog by Cancel, or the system will not correctly identify your parting curve(s).

Choose OK in the Parting Lines dialog.

How Does it Work? The parting curve should now change to a magenta color, and the Create Parting Surfaces dialog appears. This magenta color was selected for class. The default color is green, the same as the default curve creation color. We edited our defaults file to make it easier to realize when the operation has been successfully completed, and, to recognize if it was not successfully completed. The Create Parting Surfaces dialog appears now because you selected Auto Process. When you first create potential parting curves, they are placed in a named group, UM_EXTRACT_CURVES. This enables the system to easily relocate curves to MW_HideObjectLayer.

3-50




Parting Preparation

We will deal with the full set of choices that complete the identification of parting curves in a later lesson. At this point, you need to understand only that when you choose OK the process is completed properly. The arc you selected is moved to MW_PartingLinesLayer (26), category PartingLine (MW_PartingLinesLayerName). Additionally the curve is colored MW_PartingLinesColor (magenta for the class) and added to a special group, UM_PARTING_LINES. The parting lines group is used when you create parting surfaces. Step 7 Create the parting surface.

Enter 8.0 in the Distance window.

À


Á


A Warning Message appears:

Choose OK to create a single parting surface.



3-51

Parting Preparation

Step 8 Define Core and Cavity regions. Extract Regions appears because you selected Auto Process.

Parting Face

Fit the view to see the parting face.

The Extract Regions dialog is equipped with sliders to permit you to examine faces that MoldWizard has automatically determined belong to core and cavity tooling. We will study the features of this dialog more completely in a later lesson.


Use the sliders to preview the cavity and core regions.

The core region is truncated at the location of our patch body.

3-52

Choose OK to create region features and move to the next stage of the process.




Parting Preparation

Step 9 Complete the core and cavity bodies. The Core & Cavity dialog appears because of Auto Process.

0.0004

À

We will learn the features of this dia a later lesson.

From the Core & Cavity dialog choose Create Core . . . À

The Select Sheets dialog appears:

In the Select Sheets dialog choose OK.

The View Parting Result dialog appears. The displayed part has been temporarily changed to mdp_cap_core. As with the other dialogs in this process, we will learn more later.



3-53


Parting Preparation

Examine the body that was created as your core tool insert.

Choose OK in the View Parting Result dialog to return to the parting part.

The layer settings in the parting part were changed. The geometry you see now represents a sewn core trim sheet containing the parting sheet, the core region, and a seed face".


How Does it Work? The parting sheet and seed face are mutually trimmed. The seed face is oriented perpendicular to the main parting plane. This face has been in the part from the time you initiated the project. Its purpose is to act as the linking geometry between the parting part and the core tool. A similar face exists for the cavity tool. The vertical orientation of seed faces is a clever trick to be certain that they can be ed to your parting geometry no matter where in vertical space you might choose to locate them.

Make layer 1 the Work Layer, and optionally make layer 27 Invisible.

Step 10 Compensate for geometry removed by Solid Patch.

3-54

Window to mdp_cap_core.





Parting Preparation

The missing faces appear. You are seeing a Wave linked body that MoldWizard has automatically created and associated to the original patch block you created. Linked patch body Core work piece

If necessary choose Application → Modeling.

Unite the two bodies:

Select the larger, lower, core body as the target.

Select the smaller, upper, green linked body as the tool.

This completes the plan you made to compensate for faces removed from the parting part by the patch body. The core section is well suited to machine with a lathe. In a later lesson you will learn how to create a sub insert in a work piece. You may then, on your own, choose to return to this project to design an appropriate sub insert. Step 11 Save your work.

From the Menu Bar choose File Close Save All and Close. This concludes Activity 3-5.



3-55


Parting Preparation

MoldWizard Tools Dialog (continued) Sheet Patch Up (continued) There is one function under Sheet Patch up we have not examined, Enlarge Surface.

Enlarge Surface

ÏÏÏ ÏÏÏ 3 ÏÏÏ ÏÏÏ The enlarge surface function is useful for trim operations in patch up work. Enlarge Surface features can be edited using feature edit beyond the 900% maximum value of the slide controls. Another common use is to create associative parting sheets when there is a surface in the part that can be used for a single contour parting. In this situation the trim function is especially useful to adjust an enlarged face to workpiece boundaries.

3-56




Parting Preparation

The system prompts you to pick a face. A copy of the face is created, slightly larger than the selected face. This copy may have slightly different UV parameterization than the original, with the result that certain face types, such as spheres, might have a hole in the center. The dialog shown below appears:

The sliders control the expansion of the face along U and V directions, represented by cone head arrows in the graphics display. You can slide the surface larger, from 10 to 900 per cent, in either direction. This tool also appears during the Surface Split operation for trimming a solid patch. The slider settings are retained as numeric expressions and may be edited using the Edit Expression dialog. The Cut to Boundary toggle is used to trim the sheet. The system displays a point at the negative U negative V corner of the sheet. When Cut to Boundary is active the Edit Boundary, Add Boundary Face, Keep or Discard, and Edit Trim Point buttons are available. Edit Boundary allows you to add or remove trim curves. Add Boundary Faces allows you to select faces as part of the trim boundary. The Keep and Discard radio buttons refer to the section containing the displayed point. Edit Trim Point allows you to respecify the location of the point for keep and discard. The trim operations within this MoldWizard function are also available in Toolbox → Free Form Feature → Trimmed Sheet. As Existing Surface is used to automatically identify and copy the surface for use in core and cavity regions. If this toggle is OFF, the surface is a general free form sheet.



3-57


Parting Preparation

Activity 3-6: Enlarge Surface

In this activity you will use Enlarge Surface to create a natural parting face. Step 1 Create a product tooling assembly for mdp_case6.


3-58

First Part

.../case6/mdp_case6

Units

default (Inch)

Proj Name

default (mdp_case6)

Mold Csys

default


1.005

Work Piece

default

Layout

Auto Center




Parting Preparation

Step 2 Create a parting face.


This action is only to enable Undo if it is needed later. TIP If you enter the Modeling application after performing some MoldWizard operations, the Undo list will be truncated when you enter modeling. It is useful, when you think you will want to use modeling functions, to enter modeling right away after initializing, so as not to lose any Undo steps.

Choose MoldWizard Tools.

Choose Enlarge Surface.

Note: Do not confuse MoldWizard's Enlarge Surface with Insert Free Form Feature Enlarge... The MoldWizard Enlarge Surface function has several additional options.

Select and confirm the face shown in the figure below.



3-59


Parting Preparation


Enable the Cut to Boundary toggle.

Move the sliders to no more than 1% in U and 10% in V.

U and V direction indicators V U Trim Point

3-60

When the sliders are adjusted correctly, choose OK to create the enlarged sheet.

Cancel from the Tools dialog.




Parting Preparation

Step 3 Adjust the enlarged surface.


Orient View to Top.

This enables you to see the work piece insert parent body while you adjust the enlarged face. It is important to be able to judge when the face is large enough to trim the work piece. If you did not exceed the suggested UV values, it should be apparent that the surface just enlarged does not extend completely beyond the edges of the work piece. The face is a parametric feature. We can easily edit the U and V values we entered until it reaches an appropriate size.

Activate the Model Navigator.

Double-click on the icon for Patch(19) . . . À


À The Sets of Features dialog appears.



3-61

Parting Preparation


Á Â

Toggle Hide Feature Set to OFF (unchecked) . . Á

Choose OK . . Â

TIP Model features that are positioned, suppressed, or deleted together may be collected into a single Feature Set: Format Õ Group Features MoldWizard makes use of feature sets to maintain a well organized feature tree.

3-62




Parting Preparation

Double-click over the icon for Sheet body(15) . . . Ã

Ã


The Edit Parameters dialog opens.

Ä

Choose Drag . . . Ä



3-63

Parting Preparation

The Percentage Control dialog opens.

Å


Æ

Choose the U option . . Å

Use the slider bar to edit the U Extension Percentage value until the enlarged face is larger than the block, (Approximately 12-13% in the U).

Choose the V option . . . Æ

Use the slider bar to edit the V Extension Percentage value until the enlarged face is larger than the block, (Approximately 70% in the V).

Choose OK.

In the Model Navigator, there is one TRIMMED_SHEET feature and two EXTRACT_BODY features following the sheet body. These features are the result of As Existing Surface being enabled. MoldWizard automatically placed the extracted copies into the core and cavity layers, one copy to each of the two layers, and identified them for future use.

3-64




Parting Preparation

Enlarged Sheet Insert Block (Work Piece)

Body in Parting Part

With this particular contour the sheet body you created will create a smooth parting with no steps or discontinuities. If we use the normal parting method of extruding edges, the results, while certainly workable, would not be as easy to machine and maintain as this face. In a later lesson you will use this method to complete a parting trim on core and cavity tooling inserts. Step 4 Save your work.

Cancel the Model Navigator window.





3-65


Parting Preparation

SUMMARY

MoldWizard provides a versatile range of tools for creating shut off geometry. In this lesson you:


3-66

Used the Product Design Advisor to identify potential problems in a customer supplied" model.

Identified holes requiring patch up.

Used patch Tools to create shut off geometry.

Previewed compensating in a tooling part for faces removed by patch body from the parting part

Previewed using the Product Design Advisor.

Used Enlarge Surface.




Family Molds and Layout

Family Molds and Layout Lesson 4

PURPOSE

OBJECTIVES

In this lesson you will learn how to manage tooling assemblies for molds containing two or more identical or related products.


Use Load Product in an existing tooling assembly to create a family mold.

Use Layout to arrange work piece inserts.

Use the Family Mold icon to select a member product as the target for MoldWizard's utilities.

Use Layout to create a circular array of mold inserts.

ÏÏÏ 4 ÏÏÏ ÏÏÏ


Page

4-1 Family Mold Project: Toy Shapes . . . . . . . . . . . . . 4-16 4-2 Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24



4-1


Family Mold Related products are commonly formed in a single injection mold. Molds that produce multiple parts of different designs, such as top and bottom cases of a MoldWizard automatically arranges Family Mold projects into an assembly structure with a separate branch for each part. The Family Mold function allows you to select an active part" from parts that have been loaded in the family mold for the operations to follow. MoldWizard functions intended to operate on a specific part or related files are called part specific operations. Examples of part specific operations are Shrinkage, Parting, and Mold Coordinate System. The part that has the focus of attention for various functions is called the active part.


The Select Plastic Product dialog, shown above, appears when you choose the Family Mold icon while a family mold is open. If there is only one product present, the dialog will not appear and you will get a warning message. Highlight any product in the list, then choose OK, or simply double click on the name of product you wish to be active. NOTE

4-2

Moldbases and some Standard Parts such as Columns, are installed in assembly branches that are not part specific. These operations are not affected by which part model is active.





Remove Family Member The Remove Family Member button found on the Select Plastic Product dialog is used to remove a product from the family mold. This function will remove all the assembly components (shrink, parting, core, cavity, etc...) related to the product removed.

Load Product If you select Load Product when a MoldWizard top" assembly is already open, a prod" sub assembly for the new product is created below the layout" node. This new sub assembly has the standard structure:

À

Á


Â

À

The _layout" sub assembly may contain one or more product sub assemblies.

Á

Plastic Products

Â

Each product has this six part sub-assembly structure.



4-3


Load Product and Mold CSYS When a family part is loaded, it will use the Mold CSYS of the currently active part. When a product model is positioned/repositioned using the Mold CSYS function, the transformation information is recorded by MoldWizard and retained for later use. Any additional product models that are loaded will be positioned with the same transformations as the model that preceded it. Matching the transformation is useful for replacing a product model when associative changes cannot be made. In this process, a new parting set is created based on the new model. The new parting set can be linked to the cavity and core models of the original set to maintain downstream work where possible.


4-4





Layout Family molds or multiple cavity molds include two or more workpiece inserts within the mold base. Layout provides tools for easy positioning of multiple workpieces relative to each other in the mold. NOTE:

Use Load Product exactly once for each product in the mold. Use Layout to create multiple instances of products.

ÏÏÏ 4 ÏÏÏ ÏÏÏ Within Rectangle configurations inserts may be positioned as Balanced or Linear. In Circular configurations they may be oriented Radial or Constant.



4-5


Layout Methods

À

Á

Automatic Rectangular Layouts Procedure


Choose Balance or Linear

Select a number of cavities (2 or 4) . . À

Optionally enter offset distances

Choose Start Layout . . . . . . . . . . . . . Á

Choose a direction

There are two automatic" rectangular configurations, 2 cavity and 4 cavity.

4-6





2 Cavity Layout The workpiece is offset in a selected direction. If Balance is enabled, the second instance is rotated 180° from the first. Inserts may be separated by a gap. The value entered in the 1ST Dist window governs gap. A zero value means the inserts will touch. The example below shows two results for a 2 cavity layout. In each case we selected the vector indicated by the arrow at the left. The result in the center of the diagram is Linear. The result at the right of the diagram is Balanced. The same gap, or 1ST Dist., was used for both examples.

Select any one of 4 offset directions

Optional Gap, 1ST Dist.

2 Cavity, Linear

2 Cavity, Balanced




4-7


4 Cavity Layout Select the first direction. The second direction is always 90° counterclockwise from the selected vector, like the Y+ (second) axis to the X+ (first) axis. Select First Direction

¬ ¬

¬ from Four Choices

¬

¬

Second Direction is 90 Counterclockwise from the direction vector selected

Plus or minus offset distances for gaps or overlaps may be entered. Balance causes a copy of the insert in the first direction to be flipped", just as with two cavity. The third and fourth inserts are translated from the first pair. The original insert is at the upper left corner of the diagram. The downward" vector is the direction. 1ST Dist is zero, 2ND Dist. is a small positive number. Offset direction


À

Â

Á

Ã 1ST Dist. is Zero

2ND Dist. is a small plus value Second instance is: – in direction chosen – rotated 180 Deg. (Balanced) – zero gap (1ST Dist.)

4-8


Third and Fourth copies are: – 90 Deg. CCW from direction chosen – translated with no rotation – gap (2ND Dist.)




Circular Layout Procedure

Choose Radial or Constant

Enter Cavity Number, the total number of inserts

Enter Start Angle from absolute X+

Enter Rotate Angle for the total angle between all instances

Enter Radius from absolute (0,0,0) to the reference point on the first instance

Choose Start Layout

Identify a Reference Point

Circular layouts are almost completely defined. MoldWizard does compute the angle between individual instances, given a start angle, total angle, and number of instances. The Reference Point has to be considered carefully to understand what will happen. We will give some straightforward examples of arrays where the reference point is simply Absolute (0,0,0). Examples of the effect of choosing a different reference point will follow later. NOTE

Circular arrays are always built about the absolute coordinate system (ACS) of the layout part. When you load new product and faithfully to set the mold coordinate system, the ACS of the product is transformed to the ACS of the layout part.


Radial and Constant The Radial option orients components by rotation about the selected center point. The Constant option maintains the same orientation as the original insert at each position. The first instance is always oriented exactly the same as it was before the array was created, even when a start angle is specified. Cavity Number This is the total number of cavities, including the one you started with.



4-9


Start Angle Angle with absolute X+ where the first instance will be positioned. Rotate Angle Total angle from the first instance to the last. The system will automatically calculate the angle between individual instances. Radius The distance to move the first instance from the Absolute origin point along the direction specified by the start angle to the new location of the reference point. A radial pattern of five inserts, radially located to the center of each insert.

Cavity Number: Start Angle: Rotate Angle: Reference Point:

5 0.0° 360° (0,0,0)

Á

Â À 360

Before Array Radius

Ã


4-10



°



A constant pattern of three inserts over 120°, radially located to the center of each insert.

Cavity Number: Start Angle: Rotate Angle: Reference Point:

3 45° 120° (0,0,0)

Á Â

À

120 45 Radius

Before Array

Reference Point The two previous examples use the center of the insert as the point to which the array is dimensioned. We need to consider a reference point on the part cavity to which we will dimension our array. Think of making a drawing of our circular layout of inserts. We have a point on the cavity (or insert) in mind as the end point of a radius line, where the length of the line represents the array radius, and the angle of the line with the X+ axis represents the start angle. The array is always built around the Absolute Origin, rotating with counterclockwise as the positive direction. How, then, do we control exact placement of a member of the array? The solution is to select a reference point on the part cavity! When you select a reference point on the cavity, the system first translates the cavity and workpiece FROM the reference point TO absolute (0,0). Then, the cavity is transformed from that location according to the array parameters you entered.



4-11



A radial pattern of 6 inserts, radially located about a Reference Point on the cavity. Cavity Number: Start Angle: Rotate Angle: Reference Point:

6 0.0° 360° Selected as shown

Á Â

À Before Array

À

360

Ã

Á Selected Reference Point

Radius

is moved to Absolute 0,0

Â Array is created

Å °


4-12





Insert Pocket When Insert Pocket is chosen, a Standard Parts dialog will appear. The interaction of this type of dialog is discussed later in the class.




4-13


Reposition Methods Positioning of one or more inserts can be modified using Reposition functions. There are three options for manual control over product sub assemblies within a mold base layout. Rotate, Transform and Remove all operate on whichever products are selected, or highlighted. Auto Center automatically repositions the entire layout.

Rotate

ÏÏÏ 4 ÏÏÏ ÏÏÏ The Rotate Cavity dialog features Move and Copy radio buttons, a slider control to dynamically rotate the cavity about a center point, a numeric input window for exact value entries, and a Set Rotate Center button. Set Rotate Center opens the Point Subfunction dialog to pick a center point.

4-14





Transform

The Translate dialog also has Move and Copy radio buttons, and two slider controls to dynamically position an insert in X or Y. The X and Y input windows allow precise values to be input. In these windows, and the rotate input window, use the Enter key to immediately see the effect of your numeric entry. The From Point To Point button functions in the same manner as all UG transformations. You pick first at a point you want to move, and second at the position to which you want the first point to go. Remove Remove will remove an instance of the highlighted part from your layout,but only if there is more than one instance present.

ÏÏÏ 4 ÏÏÏ ÏÏÏ Auto Center Auto Center causes the system to automatically position the geometric center of the current layout, as viewed in the XY plane, to the Absolute (0,0) of the layout sub assembly. This position corresponds to the center of the mold base, where the XY plane is the principal parting, and the Z+ axis is the direction the moving half of the mold travels when opening the mold.



4-15


Activity 4-1: Family Mold Project: Toy Shapes In this project you will add several products to a MoldWizard tooling assembly.

mdp_hex

mdp_star mdp_cir

mdp_sqar

You determine that the family of toys shown above will match an existing 14x14x2 standard size used at your company if the parts are formed by four 7x7x2 insert sets. You locate the parting .875 inches above the bottom of the lower core insert, leaving 1.125 inches for the cavity Z dimension. Step 1 Create a new toys" project.


First Part

.../family/mdp_cir

Units

default (Inch)

Proj Name

toys

Step 2 Load a second part.

4-16

Open the Assembly Navigator. Use the Expand All icon or Tools Assembly Navigator Expand All. Size the Navigator window large enough to observe changes to the toys_layout sub assembly.





Choose the Load Product icon, filter to the family directory and choose mdp_sqar.

When you accept mdp_sqar the system does not ask for project information! The Assembly Navigator displays a new component: product subassembly toys_mdp_sqar_prod is created under toys_layout. Step 3 Create an insert for the currently active part.

Close the Assembly Navigator, or move it out of your way.

The two products are currently positioned at the same coordinates. We will create inserts for each, and then line up the edges of the inserts as shown below:


Choose the Shrinkage icon.

The work part changes to toys_mdp_sqar_shrink. The most recently loaded product is the active part upon which many MoldWizard functions operate. After you create an insert for the square you will shift focus back to the circle.

Enter a shrink value of 1.005, then choose OK.




4-17


The default dimensions X_length and Y_length conveniently default to 7 inches for the square product, but you need to adjust the Z_down and Z_up values.

Adjust the Work Piece Dimensions: Type: Z_down . . . . . . . . . . . . 0.875 Z_up . . . . . . . . . . . . . . . 1.125

Choose OK.

In a few moments the insert appears. Step 4 Create an insert for the circle part.


Choose the Family Mold icon:

The Select Plastic Product dialog appears. Each product in the top assembly appears in a selection list.

4-18





Double-click on mdp_cir.

Choose the Shrinkage icon.

The work part changes to toys_mdp_cir_shrink. The circle is now the active product.

TIP Choose Family Mold at any time to confirm the currently active product. Change products or simply choose Cancel to exit the dialog if the current product is the one you want to work with.

Enter a shrink value of 1.005, then choose OK.


Again, adjust the Work Piece Dimensions: Type: Z_down . . . . . . . . . . . . 0.875 Z_up . . . . . . . . . . . . . . . 1.125

Choose OK.




4-19


Step 5 Position the circle and square inserts.

Choose the Layout icon:

The Cavity Layout dialog appears:

À


Fit the view to see clearly where the system has placed both inserts.

The circle part and insert are highlighted. It does not matter which part you move. Eventually, you will use Auto Center to position your entire layout at the mold center.

4-20

Choose Transform in the Cavity Layout dialog . . À





The Translate dialog appears.

NOTE

Move the sliders, enter values, or use From Point To Point to reposition the insert.

The highlighted body shows the current destination" of the part if you accept the values shown in the dialog. When using Point to Point ignore the highlighted body. Choose points on the original, non-highlighted body. After a brief period of experimentation with the sliders it should be clear that the correct translation is 7.0 in X and 0.0 in Y. You can use From Point To Point and simply move a corner of the insert to the location where it belongs, or, type in values in the X and Y text input boxes and hit enter to update the position.




4-21


Choose OK when the inserts are positioned as shown below.

Step 6 Load the remaining toy shape products. NOTE

Make certain all four product inserts are the same size.

Repeat the preceding steps to load and position the star and hex parts. Don't forget shrinkage!


4-22





Your final toy tooling assembly structure should look like this:

Step 7 Center the layout.

After the last insert is positioned, choose the Layout icon (if necessary) to open the Cavity Layout dialog.

Choose Auto Center.

The work pieces are centered as shown in this view of the trimmed core tooling:

ÏÏÏ 4 ÏÏÏ ÏÏÏ Step 8 Save your work.

Choose File → Close → Save All and Close. This concludes Activity 4-1.



4-23


Activity 4-2: Circular Layout

In this activity you will again open your hub assembly and create a circular layout similar to the illustration below.

Step 1 Open your existing product tooling assembly for mdp_hub.


Choose File Recently Opened Parts.

Your mdp_hub_top assembly should be on the list. If not, use File Open. If needed, use this staged assembly instead: moldwizd / hub_2/


Entering the modeling application now guarantees that Undo will be available if you need it.

4-24

Make Layers 7 & 8 Selectable.





We require the lug" to face the center of the array. The lug currently lies along YC-; therefore, we want to translate the part along YC+. XC+ is 0°, thus our Start Angle (measured counterclockwise) is 90°.

We want to move this feature along YC+, so that it “points towards” the origin.

The arc centers of the inserts must lie on a 8.0 inch diameter circle, 6 cavities equally spaced. This dictates 4.0 as the Radius, and 6 as the Cavity Number.

60 Typ. ∅ 8.000


You could calculate the required layout parameters using the information in the above illustration.



4-25


Step 2 Create a circular layout.

Choose the Layout icon.

Enable the Circular option. Radial should be enabled by default.

Enter the parameters shown in the chart and illustration below: Type: À Cavity Number . . . . . . . . . . . Á Start Angle . . . . . . . . . . . . . . . Â Rotate Angle . . . . . . . . . . . . . Ã Radius . . . . . . . . . . . . . . . . . .

6 90 360 4.0

À Á Â Ã Ä


4-26

When the values are entered, choose Start Layout . . Ä





The Point Constructor appears.

Since the dimension for the radius is given to the center of the insert, choose Arc/Ellipse/Sphere Center, and then select either the upper or lower circular edge of the insert . . À


À

À

Fit the view.



4-27


You chose 90 as the Start Angle to set YC+ as the direction that the part was translated before the array was created. XC+ is by definition at start angle 0.0°. The angle is measured counter clockwise, thus YC+ is at 90°. Rotate Angle is 360° because you want a complete circle of six inserts. The system calculates the incremental angle between instances. As soon as you choose a reference point the system creates the layout specified.


Choose Cancel to exit the dialog.

Optionally, Undo your work, and experiment with different circular array parameters. This project is not needed again.

Please Close all parts when the allotted time for the activity period has ed. This concludes Activity 4-2.

4-28





Removing the only instance of a product The layout function does not provide the ability to remove the only instance of a product from a MoldWizard assembly. The following step by step procedure is provided for anyone who is not fully comfortable with Unigraphics assemblies functionality. Procedure:

Make the layout part the work part.

Close all product related parts using either File Close Selected Parts, or the Assembly Navigator. Related parts consist of the prod" sub assembly with its shrink, parting, core, cavity, and if necessary, the original product part. Removed component parts still open in memory would reappear on disk after a Save All.

Remove the prod" component from your Layout sub assembly

Select the component in the Assembly Navigator

Choose Edit Delete

A warning will appear that component(s) will be removed, but the parts will not be deleted.

Remove the prod" part and its child parts from your project directory manually using your operating system. Removed component parts that are still present in your project directory can cause future problems if you decide to add the product again. When you first closed the parts from memory, you prevented the possibility of them reappearing in your directory due to a Save All.

Save All. This saves the assembly structure as modified. If you fail to save after the above steps, you will get error messages about missing component parts when you next open your assembly. If you had failed to close the unwanted parts from memory, they would reappear in your project directory at this point.



4-29



SUMMARY

MoldWizard provides useful tools to create and configure family and multiple cavity molds. When you have multiple products, only one is the active product, or, the target for various MoldWizard functions. When you have multiple instances of one product, to use Layout rather than Load Product to create additional instances. In this lesson you:

Used Load Product in an existing tooling assembly to create a family mold.

Used Layout to arrange related work piece inserts.

Used the Family Mold icon to select a member product as the target for MoldWizard's utilities.

Created a circular layout.


4-30




Core and Cavity Definition

Core and Cavity Definition Lesson 5

PURPOSE

OBJECTIVES

You will learn how to identify or create parting geometry and define the regions of your part model to be formed by core or cavity tooling. You will complete the topic by creating associative tooling bodies, including sub inserts.


Identify parting edges and curves.

Identify transition objects.

Construct and Edit parting surfaces.

Identify defined parting sheets.

Extract core and cavity regions.

Create linked core and cavity models.

Use Enlarge Surface to create a simple Parting.

Create Sub-Inserts


Page

5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9

5-11 5-16 5-25 5-42 5-70 5-74 5-81 5-86 5-101

Parting Curves on a Planar Parting . . . . . . . . . . . . Natural Parting with Isocline Curves . . . . . . . . . . . Selecting Transition Objects . . . . . . . . . . . . . . . . . . Parting Surface Creation . . . . . . . . . . . . . . . . . . . . . Core and Cavity Regions . . . . . . . . . . . . . . . . . . . . . Diagnostics in the Extract Regions Dialog . . . . . . Defined Parting . . . . . . . . . . . . . . . . . . . . . . . . Topology Change to Product Model . . . . . . . . . . . Compare and Swap . . . . . . . . . . . . . . . . . . . . . . . . .



ÏÏÏ ÏÏÏ 5 ÏÏÏ ÏÏÏ 5-1


Parting MoldWizard offers a suite of functions that simplify construction of parting surfaces and provide the potential to maintain associativity when product models are modified or replaced. The Parting Functions dialog appears when you select the Parting icon:

Auto Process When activated, automatically chooses the four main buttons Parting Lines, Parting Surfaces, Extract Regions, and Cavity & Core, in sequence. As you complete tasks inside each submenu, MoldWizard displays the next submenu from the dialog above.


The setting of Auto Process when the dialog appears (checked or unchecked) is controlled in mold_defaults by MW_PartingAutoProcess. A value of 1 will enable the option by default, and a value of 0 will make the option disabled by default. We chose to uncheck the option by default for this class.

5-2





Parting Lines When you select the Parting Lines button in the Parting Functions dialog, the following menu appears.

The Parting Lines dialog contains tools with which you identify Parting Curves and Edges. Using Auto Search Parting Lines, MoldWizard identifies existing edges that are appropriate for modeling parting surface. Split Faces allows you to detect and remedy some situations where the natural parting for the part occurs across a face as opposed to along an edge. The Transition Objects area provides tools to define and edit transition geometry or corner points". The system will typically fill in" areas adjacent to transition objects with swept or planar faces.



5-3



Auto Search Parting Lines

When you choose Apply in the Search Parting Lines dialog, the system will:

detect, in most cases, the single best parting loop

the Product Design Advisor becomes available

if holes are detected, Auto Patch becomes available.

Select Body If the part contains multiple solids use the Select Body button to choose a body to be analyzed for parting curves.

Eject Direction The ejection direction is usually by choosing a mold coordinate system. By default, MoldWizard will assume the Z axis of the WCS is the eject direction. You may specify an ejection direction within the Search Parting Lines dialog.

Product Design Advisor and Auto Patch


The functionality here is identical to the Product Design Advisor and Auto Patch offered within the MoldWizard Tools dialog and was covered in lesson 3. They are also presented here as a convenience to the .

5-4





Traverse Loop From the Parting Lines menu, you can use Traverse Loop to select parting curves and edges manually. NOTE

This option is helpful when you have a model where the edges are disted and non-contiguous in places. This is most often the case when you are developing a mold for a part modeled in another CAD system and translated to Unigraphics.

From the Parting Lines menu, use Traverse Loop to select parting curves and edges manually. With Smart Traverse enabled, a continuous parting line segment is automatically detected when you select one curve or edge. It continues around the part until parting is unclear due to gaps or the lack of an edge at the next anticipated parting position. If you select an edge that should not be include in parting, the status line will display Not a potential parting line, try another one ...". The initial setting of Smart Traverse is controlled in mold_defaults by MW_PartingSmartTraverse. A value of 1 will enable the option by default, and a value of 0 will make the option disabled by default.

ÏÏÏ ÏÏÏ 5 ÏÏÏ ÏÏÏ EDS All Rights Reserved


5-5


Edit Parting Lines

Curves and edges may be added to or removed from the parting line definition manually.






Split Faces

When a face from your model can be seen from both the core and cavity sides of the mold it is referred to as a Crossover Face. Since MoldWizard uses edges to create parting curves and subsequently the parting surfaces it is necessary that the crossover faces be split or subdivided.

Inspect Crossover Faces Choosing Inspect Crossover Faces will highlight all faces in the model that cross over parting.



5-7


Split Faces by Imprinting If Selected Faces is toggled, the faces the selects from the graphics screen will be the only faces split. If Connected Faces is toggled, all faces that intersect the defined plane will be split.

Existing Datum Plane allows you to select a datum that is positioned where you want the split. Point + Point will allow you to select 2 points that will define a line which will be used to split the faces. Point + X-Y Plane will split the faces paraĆ lell to the XY plane at the point selected. Subdivide Isocline Faces When Subdivide Isocline Faces is selected the system will display all potential isocline curves to use for subdividing the faces. You have the opportunity to deselect curves that do not relate to the parting. When you accept the remaining highlighted curves, the system will subdivide all adjacent faces at the isoclines. After subdividing, one part of the face will be on the core" side and the other part on the cavity" side.

Transition Objects Transition Objects are points or curves along the parting loop which define the extents of parting edges which can be extruded in a single direction to form a parting sheet. Transition curves are sometimes used to define bridging surfaces between adjacent extruded sheets.


Curve segments that rise above or drop below an otherwise single face" parting are very useful as transition objects.

Transition objects are frequently located at corners" of a parting loop.

Transition objects are not needed for planar partings.





Transition Objects Transition Objects are points or curves along the parting loop which define the extents of parting edges which can be extruded in a single direction to form a parting sheet. Transition curves are sometimes used to define bridging surfaces between adjacent extruded sheets.

Curve segments that rise above or drop below an otherwise single face" parting are very useful as transition objects.

Transition objects are frequently located at corners" of a parting loop.

Transition objects are not needed for planar partings.

Auto Transition Objects

Auto Transition Objects assists you by automatically detecting parting curves that belong together" such as coplanar curves or curves with a common parent face.

ÏÏÏ This function allows you to select and deselect curves in the parting loop. When ÏÏÏ 5 you OK the dialog, selected curves are identified as transition objects. ÏÏÏ ÏÏÏ Edit Transition Objects



5-9


Add Transition Points If you have sharp corners you probably need to define Transition Points.

NOTE

If all Parting Curves lie in a plane you do not need to specify transition objects. The system will automatically create one single bounded plane. You saw an example of this feature in the introductory activity.

If Parting Lines consists of a single 3D Curve (circle, ellipse), you do not need to specify parting line segments.






Activity 5-1: Parting Curves on a Planar Parting

In the next group of activities you will experience different parting possibilities and methods to handle them. The first part has a simple planar parting. Step 1 Create a mold project for mdp_outlet.

First Part

.../outlet/mdp_outlet

Units

default (Inch)

Proj Name

default (mdp_outlet)

Mold Csys

default


1.008

Work Piece

default

Layout

Auto Center


Step 2 Define the parting lines.




5-11


From the Parting Functions dialog choose Parting Lines → Auto Search Parting Lines.

Choose Apply to begin processing.

MoldWizard quickly finds and displays the natural parting edges of this simple part.

Choose Auto Patch.






À

Deselect an edge loop opening on one of the screw posts, as shown above . . À Hint: Change to wireframe display, if necessary.

The missing patch face will later provide an example for diagnostics in the Extract Regions dialog.

Á Â

Choose Auto Patch . . . Á

All openings except the one you deselected are patched.


You may shade the view to patch creation.

Choose Back . . . Â



5-13


Choose OK in the Search Parting Lines dialog . . Ã

Ã Tentative parting lines are displayed in green as the Parting Lines dialog appears. At this point, in a more complex part, we could perform editing or define transition objects. Parting Line definition is not complete.

Choose OK one last time, from the Parting Lines dialog.

The lines change color to magenta as the Parting Functions dialog is displayed.


We will work with other parting line examples before returning to complete the outlet project.

5-14





Step 3 Display the parting body before saving your work.

Cancel the Parting Functions dialog.


Fit the view if necessary.


Choose OK to acknowledge that you really want to save and close all parts. This concludes Activity 5-1.



5-15


Activity 5-2: Natural Parting with Isocline Curves

The next part has no edges that can be used for a parting. It is our familiar plastic cup, without the holes we added to demonstrate patching. You will use Isoclines to divide a blend face at the natural" parting.

Step 1 Create a mold project for mdp_cup1.


First Part

.../cup1/mdp_cup1

Units

default (Inch)

Proj Name

default (mdp_cup1)

Mold Csys

Specified Later!


Specified Later!

Work Piece

default

Layout

Auto Center





Recall that the positive Z direction indicates the direction the part will be ejected from the mold. A part of this type will tend to shrink and grip the core as the mold opens, requiring ejection to be off the core side. To efficiently mold this part, the cup needs to be inverted. This will require a Mold CSYS rotated 180 degrees about the YC Axis.

Step 2 Set the Mold CSYS to reflect ejection off the core side of the mold.

Choose WCS → Rotate...

Select +YC Axis: ZC→ XC and set the angle field to 180 degrees.

Select OK.

The positive ZC axis should now point down and away from the bottom of the cup.





5-17


The Mold CSYS dialog opens:

À Á

Set/ that Current WCS is toggled ON . . . À

Choose OK . . Á


Fit the view.

The eject direction ZC+ will now remove the part from the core. The XC-YC plane lies on the flat bottom of the cup. This is not the correct parting plane. In fact, the parting plane for this part does not lie at any existing edge geometry. In this, and similar cases where the parting is not defined by obvious geometry, a natural parting must be defined before establishing the Mold CSYS. Step 3 Define parting lines.



The Parting Functions dialog opens.

5-18

From the Parting Functions dialog, choose Parting Lines.






From the Parting Lines dialog, choose Auto Search Parting Lines.

The Search Parting Lines dialog opens.

Choose Apply.

The MoldWizard system finds an edge . . . À In this case, we know the natural parting occurs at the vertical location of the blend face, as shown below . . . Á The edge, shown as a dashed line in the illustration, is well within a fixed distance tolerance for undercuts, but is not precisely the natural parting.

ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ À ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ Á ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ What if the part ÎÎÎÎÎÎÎ were not so simple. Could MoldWizard reveal this information?

The Product Design Advisor has become available. It is a good habit to check the Advisor even when you do not suspect problems.



5-19


Choose Product Design Advisor.

Select Crossover Faces.

The MoldWizard system found one crossover face, and highlighting reveals it is the blend. This is our cue to subdivide the crossover face at the zero degree Isocline curve.


Choose Back to return to the Search Parting Lines dialog.

Choose Back once again to return to the Parting Lines dialog.





Choose Subdivide Isocline Faces.

The system finds the isocline of the blend, the only crossover face in the part. The Deselect Isoclines function is active:

NOTE

Choose OK to accept the highlighted isocline curve for further processing.


Choose Apply.

The above step is important. You need to dismiss the edge found earlier and identify a new edge, at the isocline position, as the parting curve.

Choose OK in the Search Parting Lines dialog to continue processing.

Choose OK to exit the Parting Lines dialog and accept the displayed circular spline as the parting loop.

The selected loop changes color to magenta, or whatever color is defined as MW_PartingLinesColor.



5-21



Cancel the Parting Lines dialog.


Step 4 Examine the new split line at the lip of the cup.

Zoom in on the lip.

If curve detail is lacking. depending on your hardware, you can Update Display (using MB3), or use View Operation Regenerate Work, to see both the original blend edge and the new parting edge.

From the main menu select Information Object Type Edge.

Select the magenta parting edge. The Information window identifies this edge geometry as a tolerant curve.

Cancel the Information window.

From the main menu select Information Object Type Curve.

Select the magenta parting curve. The Information window identifies this curve type as a spline.

The curve is a spline. The system extracts the edges of the split face as splines, to make it easier later to identify their parent face. The original isocline was an arc, and it is currently hidden. The original isocline arc is in layer 255, MW_HideObjectLayer. Of all the available geometry at the natural parting, the arc is best suited to orient our mold csys.


5-22

Cancel the Information window.





Step 5 Display the top part.

Choose Window → More Parts...

Select mdp_cup1_top, then OK.

Set the display to a Front view. Zoom Out if necessary to view the WCS.

The orientation of the Mold CSYS was defined to allow for ejection off the core side of the mold. The natural parting line was defined and examined. The principal XC-YC parting plane now needs to be moved to the natural parting plane and the Mold CSYS redefined. Step 6 Move the WCS to the Natural Parting plane and redefine the Mold CSYS.

Zoom in on the part as shown below:


Choose WCS → Origin... and use the Arc/Ellipse/Sphere Center function to move the WCS to the center of the Natural Parting Curve.



5-23


Choose the Mold CSYS icon. The Mold CSYS dialog opens.

Select/ that Current WCS is toggled ON and select OK.


Make Layer 255 Invisible.

Fit the view.

Step 7 Set the Shrinkage Factor to 1.008. NOTE

It is important that the orientation and placement of the Mold CSYS be established prior to asg a Shrinkage Factor. In cases where the parting line/plane is not obvious, first define the principal parting plane, adjust the Mold CSYS, and only then assign Shrinkage.



From the Menu Bar choose File → Close → Save All and Close.

Choose OK to acknowledge that you really want to save and close all parts. This concludes Activity 5-2.

5-24





Activity 5-3: Selecting Transition Objects

The part is another cup. This one has a step" in the parting. You will practice selecting transition objects in a non-planar parting loop.

Step 1 Create a mold project for mdp_cup2. First Part

.../cup2/mdp_cup2

Units

default (Inch)

Proj Name

default (mdp_cup2)

Mold Csys

default


1.008

Work Piece

default

Layout

Auto Center





Step 2 Define parting lines.



Choose Apply.

The system finds four parting curves, including the same circular edge it first identified in the cup1 part. Does the circular edge identified lie in the Core or Cavity? This information will soon be important. The undercut distance is only .0006 inches, just over .015 mm. This distance is less than an internal tolerance. We can safely ignore this very slight undercut.

Choose OK to accept the four edges displayed above and return to the Parting Lines dialog.

There are several ways to approach parting construction in this example. The basic scenario we will use for this part will produce a parting that is acceptable in many situations. We will later try other approaches. We will use the arc to define a principal parting plane. The edges of the cut out" segment define a transition area" which MoldWizard will automatically sweep to complete a parting surface. This approach is used when parting contours should extend all the way to the edge of the work piece.






Step 3 Define transition curves.

Choose Auto Transition Objects.

À Á

Choose the Cavity Faces option . . . À

Earlier, you observed that the parting curves were on the exterior or cavity face of the cup. The observation was important because it now helps us to determine the Face Preference. This is a relatively rare case where the desired result is obtained only with the correct Face Preference option, Cavity Faces, because one of the curves lies on cavity faces.

Choose Show Coface Segments . . Á

NOTE: The Show Coface Segments option must be chosen even if it is already highlighted as enabled.



5-27


Á À

Â Three segments are identified: À the arc at the lip of the cup Á two lines that lie on the outer conical face Â an arc that also lies on the outer face. Segment dividing points are created where adjacent curves are not tangent.

Choose Convert Transit Objects.

All three curves in the cut out" section adjacent to the conical face of the cup are identified as transition curves. The interior" points of the segment are removed. Transition curves are displayed in MW_PartingTransitObjectColor, olive by default. In a later operation, this area of the parting will be automatically constructed as a sweep surface.

À

Á

Â


Choose OK to exit the Auto Transition Objects dialog.

Choose OK to exit the Parting Lines dialog.





The system will return to the Parting Functions dialog. All parting curves, including transition curves, should change color at this time, indicating that the system has added them to the UM_PARTING_LINES group. We remind you again that this color was customized for the class. The default setting is green, the same as the default curve color. Changing the color provides a good visual cue to help to avoid errors. Step 4 Display the parting body before saving your work.

Cancel the Parting Functions dialog.


Fit the view.


Choose OK to acknowledge that you really want to save and close all parts.

In a later activity you will create a parting sheet that extends to the outer perimeter of the work piece, as shown below.





5-29


Parting Surfaces

This function creates parting trim sheets for core and cavity. Sheets may be interactively constructed by a number of methods. There is also provision within the final step in the process, Sew Surfaces, to identify manually created sheets. Tolerance This value is used as both surface creation and sew tolerance. Distance The intent of this value is to make certain the parting faces are big enough to trim the insert. The default is usually a good value. If you need to enter a value, choose a distance large enough to exceed the size of the insert, plus a safe margin for changes.


NOTE

5-30

You may edit the parting extrusion distance using the expression editor. Change the variable named parting_extrude_distance in the parting part file.





Create Parting Surfaces Creating parting surfaces is a two step process.

In the first step, either use automated tools to create sheets directly from identified parting curves, or, create your own sheets.

In the second step, sew the parting sheets together to form a continuous boundary from the parting body to the extremities of the work piece.

MoldWizard will analyze previously identified parting curves. Depending on the result of that analysis, the Create Parting Surfaces dialog might appear, and may contain one or more applicable options. For planar parting curves with no transition objects, the system will not display the parting surfaces dialog. Instead, you will see the dialog shown below, from which you may elect to create a single parting surface by choosing OK. Choose Cancel if you want to go back and identify transition curves:

You saw the above dialog during your mdp_tray preview activity.



5-31


Extrude

Choose Extrude when a parting line segment, or set of curves between transition objects, can be extruded in a single Extrude Direction. Extrude uses the Distance parameter. Extrude Direction When you choose the Extrude Direction button you are presented with the standard Vector Constructor dialog:

Skip


If you do not want to a create a surface for a parting line segment, by the segment by choosing Skip.

5-32





Bounded Plane The option to create a local bounded plane" appears if planar segments are detected. A segment" consists of all the parting curves between, but not including, a pair of transition objects. Bounded plane is used when:

No single extrude vector direction is possible.

The angle between directions is greater than 180°.

When you select Bounded Plane, the available buttons change as shown below:

When the bounded plane dialog options appear, the system is ready for an interactive sequence to define the extents of a bounded plane."

The system temporarily displays a 1" and a 2" at the ends of a highlighted parting segment.

Choose First Direction.

Use the Vector Constructor to define a Trim Line" extending from the parting segment end numbered 1. In the example shown on the following page, the First Direction will lie along the +Y Axis.



5-33



1

First Direction defines the orientation of a “trimming line” extending from this point

2 Highlighted Parting Segment

Once the First Direction is established, additional controls are added to the dialog, as shown below:






Select Second Direction to open the Vector Constructor dialog and define the orientation of the trimming line" that extends from point 2. In this example, the Second Direction will lie along the -Y Axis. 1 First Direction

+ Region Point

2

Second Direction

Select OK to accept the Second Direction definition and return to the Parting Surface dialog.

Select OK again, this time in the Parting Surface dialog. The View Trimmed Sheet dialog will open and one of two parting surface configurations will display.

Select to view alternate sheet

When the correct sheet configuration is displayed, Choose OK to create the parting sheet.

The correct sheet configuration for this example is shown below:



5-35


Swept

Swept is used when:

No single extrude vector direction is practical.

The angle between directions is less than 180°.

The swept option, as the name implies, sweeps the profile along two lines which extend Distance" along directions you specify.

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ Bounded Plane

Choose Sweep for these segments sides. We specify two directions as

This Transition Segment will automatically be swept to fill the area between two swept edges. D

First Direction


These Transition Segments, one on each side, will be swept to fill the area between a swept edge and an edge of the bounded plane. Second Direction

5-36



Second Direction



Enlarged Surface When a segment is detected with a single parent face, you have an option to create an enlarged surface. The Enlarged Surface dialog behaves similarly to the Bounded Plane option. Instead of a being a flat face, the parting face will have the shape of the parent face of the curves in the highlighted parting line segment. (The option will appear only when all curves in the segment have the same parent face.)

We noticed earlier that MoldWizard creates extracted edge curves in place of isocline curves when defining partings. We stated that the system needs to efficiently determine the parent faces of parting curves. We now see that providing the ability of the system to determine the parent



5-37



faces of parting curves enables the display of Bounded Plane and Enlarged Surface parting functions when they are applicable. The system will recognize when a segment is planar, or when all curves in the segment belong to a common face. Occasionally, all curves in a segment will belong to two common faces, one face on either side of the curve string. If that situation happens, the dialog will display an additional option, Flip Face. This enables you to toggle between the two possible faces that belong to the curve string.






Choosing a Parting Surface Type MoldWizard highlights parting segment

ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ Planar Face?

No

ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÎÎÎÎÎÎ ÎÎÎÎÎÎ

ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ

BOUNDED PLANE

SWEPT

Yes

1 Direction Practical?

No

Angle between directions < 180°?

No

ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÎÎÎÎÎÎÎ ÏÏÏÏÏÏ ÎÎÎÎÎÎÎ ÏÏÏÏÏÏ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ

Yes

EXTRUDE

ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ Yes

Same Surface?

No

Yes


ENLARGED SURFACE

No

Yes

SWEPT

EXTRUDE


ÏÏÏ ÏÏÏ 5 ÏÏÏ ÏÏÏ MoldWizard Design Process Student Manual

5-39


Edit Parting Surfaces The system will prompt you to pick a parting line or a transition object. The system will identify the child parting face of the object you select, and present the appropriate editing dialog for that sheet.

Sew Surfaces Sew Surfaces automatically selects all system generated parting surfaces. You will be presented with a Select Sheets prompt, from which you may add or remove surfaces, including sheets that were not created by the MoldWizard system. Click to select, or shift-click to deselect. When you choose OK in the Select Sheets dialog, the system will sew all sheets. You must use the Sew Sheets function even if you have only defined partings. When you select sheets, no matter how they were created, MoldWizard applies attributes to identify them as parting faces. The original sewn feature is identified for later use in the core trim sheet. The system extracts a copy to use in the cavity trim sheet.






Auto Cavity_Core

The Auto Cavity_Core function automates the process steps of Sew Surfaces, Extract Regions, Create Cavity and Create Core. This function can be applied only to a non-planar parting condition that requires sewing. To apply the Auto Cavity_Core function, follow the normal MoldWizard Design process up to and including the creation of parting lines and non-planar parting surfaces. Selecting the Auto Cavity_Core option will then launch an automated process for creating a finished cavity and core.



5-41


Activity 5-4: Parting Surface Creation

Step 1 Create a mold project for mdp_dryer.


First Part

.../dryer/mdp_dryer

Units

default (Millimeter)

Proj Name

default (mdp_dryer)

Mold Csys

specified later!


1.008

Work Piece

Wait for Mold Csys!

Layout

Wait for Mold Csys!

5-42

After you set shrinkage, set mdp_dryer_top as Work Part. Hint: Assemblies Context Control Set Work Part Displayed Part.





Step 2 Orient the WCS in two stages.

From the Menu Bar choose WCS → Rotate...

Choose the radio button -YC Axis: XC->ZC.

that the Angle value is 90.0000.

Choose Apply.

Choose the radio button +ZC Axis: XC -> YC.

Choose OK.

The WCS should be oriented with YC+ along the handle, XC+ pointing toward the nozzle and ZC+ pointing toward the vent area.


The Mold CSYS dialog opens.

Set or that Current WCS is ON . . . À

Choose OK . . Á

À

Á



Fit the view.



5-43


The system aligns the WCS of the product subassembly with the ACS of the mold assembly. The dryer should be now be oriented as shown below in the TFR-TRI view or Trimetric view orientation.

Step 3 Complete the remaining initialization steps.

Accept the defaults for Work Piece.

Auto Center the Layout.

Fit the view.

Step 4 Investigate the parting properties of the product model.

Choose Parting → Parting Lines → Auto Search Parting Lines.


After a few moments MoldWizard finds 23 parting edges.


Both Product Design Advisor and Auto Patch have become available.

5-44





Choose Product Design Advisor and check Vertical Faces.

The system detects six Vertical Faces, two for each of the three button openings. There are three button openings in the handle, and eleven vent openings in the fan housing. These openings require patching.

Compare Cavity Patch Loops and Core Patch Loops.

The system identifies the same fourteen patch loops for both the Cavity and Core side of the mold. This indicates that enough draft has been included in the part design to remove any ambiguity concerning where the patch sheet bodies should be located.

Choose Back from the Product Design Advisor dialog. The Search Parting Lines dialog displays.

Step 5 Auto Patch the holes. TIP In some cases where Auto Patch would create a large number of Edge Patches, manual patching using another method is faster.

Choose Auto Patch.

The Patch Loops Selection dialog opens.



5-45


The Cue reads: Select a patch method. Recall that in cases where sufficient draft is designed into the part, MoldWizard will always defer to what it determines to be the correct patch location (core side or cavity side). In this example, MoldWizard will correctly locate the patch surfaces (on the cavity side) regardless of the Patch Method specified. The status window reads: Found 14 patch loops. Deselect those loops that you don't want to patch. This activity uses all 14 patch loops.

Set the Display Mode to Shaded.

Choose Auto Patch . . . À

À

MoldWizard patches the button and vent openings in a manner consistent with the draft that was designed into the part model.






Patches now cover the three Button and eleven vent openings.

Set the Display Mode back to Wireframe.

Choose Back to return to the Search Parting Lines dialog.

Choose OK again, in the Search Parting Lines dialog . . . À

À

The Parting Lines dialog opens and the tentative parting line displays in green.



5-47



Step 6 Define transition curves.

From the Parting Lines dialog choose Auto Transition Objects.

Eight points of transition display.

Accept the default settings by choosing Convert Transit Objects.

The six curves shown in the figure below highlight in olive. These are the transition curves that do not lie on the XC-YC plane.

Three lines in this area À

Á

This arc

Â

Ã Ä Å Two tiny draft lines in these locations

Choose OK to exit the Auto Transition Objects dialog and return to the Parting Lines dialog.

Choose OK one last time, from the Parting Lines dialog.

The Parting Functions dialog reappears and the parting lines change to magenta.






How Does it Work? MoldWizard re parting curves you select by creating a named group, UM_PARTING_LINES. MoldWizard identifies transition points by placing them into a named group UM_TRANSIT_POINTS. MoldWizard identifies transition curves by asg a name attribute, UM_TRANSIT_CURVES, to each transition curve. Step 7 Create the front planar parting surface.

From the Parting Functions dialog choose Parting Surfaces.

Choose Create Parting Surfaces . . À

À


The Parting Surfaces dialog appears. Bounded Plane is automatically selected.



5-49


One of two possible parting segments highlights:

Â Á Á Front Segment Â Rear Segment

We will create the Front Segment/Surface first.

If the Front Segment is not highlighted, simply select it on the graphics screen . . . Á

MoldWizard allows you to create parting sheets in any order, by highlighting the segment with which you wish to work.

Choose First Direction . . . Ã

Ã


The Vector Constructor dialog opens.

5-50





First Direction defines the direction of the parting surface edge that that will extend from the endpoint of the segment labeled 1. NOTE

The numbers 1 and 2 may be reversed in your part file.

2

1

In Vector Constructor dialog, choose an appropriate direction for the point labelled 1.

Choose OK.

Fit the view.



5-51


Vector Arrows and dashed lines appear in the specified direction.

U

V

2 1






The Parting Surface dialog updates to reflect new choices:

Ä

Choose Second Direction . . . . Ä

The Vector Constructor dialog reappears.

From the Vector Constructor dialog, choose an appropriate direction for the point labelled 2.

A Vector Arrow appears in the matching direction.

Choose OK in the Vector Constructor.



5-53


The Parting Surface dialog reappears. The display updates.

U

V 2 1

Select OK again, in the Parting Surface dialog . . . Å

Å


The View Trimmed Sheet dialog opens and one of two possible parting surface configurations displays.

5-54





Choose Flip Trimmed Sheet as necessary to view the two trim sheet alternatives . . Æ

Æ

Ç

È

When the correct sheet configuration is displayed . . Ç choose OK in the View Trimmed Sheet dialog . . . . . È

Step 8 Create the rear planar parting surface.

In the Parting Surfaces dialog choose First Direction.

The Vector Constructor dialog opens. First Direction defines the direction of the parting surface edge that extends from the endpoint labeled 1.



5-55



NOTE

The numbers may be reversed in your part file.

In Vector Constructor dialog, choose an appropriate direction for the point labelled 1.

Choose OK.

Fit the view.

The Parting Surface dialog updates.

2

1

Vector Arrows appear in the matching direction.

Choose Second Direction.

From the Vector Constructor dialog, choose an appropriate direction for the point labelled 2.

A Vector Arrow appears in the matching direction.


Choose OK.





The Parting Surface dialog once again displays. Vector Arrows have appeared in the matching direction.

U

V

2

1

Choose OK in the Parting Surface dialog.

The View Trimmed Sheet dialog opens and one of two possible parting surface configurations display.



5-57


If necessary, use Flip Trimmed Sheet . . À to obtain the correct configuration . . . . Á and then choose OK . . . Â

À Â

Á

When the second planar sheet configuration is accepted, the system creates the second sheet and two transition sheets:






Step 9 Examine the sheet body that extends from the electrical cord opening. The sheet body that extends from the electrical cord opening appears to have three faces.

Choose Information Object Type Face.

Select one of the faces of the sheet body that extends from the electrical cord opening.

This sheet body has a single face.

Shade the part and Zoom In to observe how the sharp edges were rounded.

A very brief explanation of how tolerance is used in free form sweep situations follows.



5-59


When MoldWizard creates a sweep of two or more transition curves, it uses the modeling tolerance specified in the Create Parting Surfaces dialog.

The sweep function creates a spline to approximate the given section curves. This spline is internally smooth. Near sharp corners, it is constrained to lie inside the tolerance zone.

Tolerance Zone uses the Tolerance value on each side of input curves

At sharp corners, the section curve is approximated according to the rule shown above. The single face sheet could be inconvenient for an NC operation. Free Form Swept surfaces may have a zero tolerance. With a zero tolerance Unigraphics does not approximate the section string as one curve. A separate face is created for each curve. NOTE

This edit is desirable if adjacent edges are not tangent. For more information please refer to the On Line Help for Free Form Swept surfaces.


Return the Display Mode to Wireframe.

Fit the view.





Step 10 Edit the sweep parameters.

Cancel from the Create Parting Surfaces dialog.

Choose View Model Navigator, or, choose the icon:


Use highlighting to locate the PARTING_SWEPT feature that corresponds to the electrical cord opening.

TIP Use MB1 to select a line in the Model Navigator. The corresponding feature will highlight on the graphics screen.

NOTE

Your feature numbers may differ from those depicted.

À

NOTE

Double-click the appropriate PARTING_SWEPT icon . . . À

Do not click the check box - that suppresses the feature.

TIP When you double click in the Model Navigator, it is best to click over the icon, as shown above. If you click over the name, and do not click fast enough, the system assumes you want to rename the feature!





The Edit Parameters dialog appears:

Choose the Tolerance button . . . Á

Á

Type 0 (figure zero) as the new Tolerance . . Â

Choose OK . . Ã

Â Ã

Choose OK again in the Edit Parameters dialog.

The part updates with three faces, one for each curve at the electrical cord opening.


This can be verified by repeating the Information actions.

5-62





NOTE

The Tolerance in the Create Parting Surfaces dialog is also used for trim and sew tolerance. It is not appropriate to enter a zero value there. In fact, it is not allowed.

Dismiss the Model Navigator window.

Step 11 Sew the parting sheets.

Choose Parting Parting Surfaces.

Choose Sew Surfaces . . À

À



5-63


NOTE

Sew Surfaces is an essential step in all cases where there are more than one parting sheet.

The system gives you the opportunity to:

add defined sheets

remove redundant sheets


Step 12 Display the shrink body before saving your work.


If you wish, adjust the view orientation and zoom factor before saving.

Select File Close Save All & Close. This concludes Activity 5-4.






Extract Regions

Previously defined parting lines and surfaces will be used as boundaries as the system extracts regions", or bounded groups of faces, from the parting part. These regions are assigned to either the cavity or core side of the mold insert, and subsequently used to trim the cavity and core seed blocks into the shape of the product and parting.



5-65


In the Extract Regions dialog, the total number of faces on the parting part and the numbers of cavity and core faces are displayed. The total should equal to the sum of cavity and core faces. Two slide bars make previewing and checking cavity and core faces easy. If Total Faces is less than the number of core and cavity faces combined you probably have an un-patched hole. Using the slides to slowly highlight one region, you can easily spot where the hole is. Face highlighting will suddenly enter the other" region (Core or Cavity) as you highlight faces in or adjacent to the hole.


If the total faces is greater than the sum of core and cavity region faces, you may have created an internal empty volume (with solid patch) or you might have created duplicate patch surfaces. Correct the error before proceeding.

5-66





TIP If you have manually prepared faces for core and cavity regions, any face that crosses the parting must be split or subdivided.

Rarely, the system might not interpret the parting boundary as you want it. You can modify the system selected cavity and core boundary edges or faces. Four radio buttons, Cavity Only, Core Only, Both, and Boundary Edges, control boundary editing selections. Various buttons on the dialog are available depending which option is active. In edit mode, you may Select or Shift-Deselect boundary faces or edges.

TIP Try to use a simple region boundary to edit. Depending on the

product shape, sometimes one region boundary is easier to edit than the other. Try to avoid using the Both option because you will need to edit two region boundaries instead of one.

The default Edit Boundary setting is Boundary Edges. This can be modified in the mold_defaults file by editing the value of MW_PartingRegionType. MoldWizard automatically identifies core and cavity regions based on surface normals and the ZC+ direction. In very rare cases it is not clear which subset of the part faces belong to core or cavity. If this occurs you will be prompted to select a seed face for the region(s) that could not be determined. When you choose OK in the Extract Regions dialog, MoldWizard automatically creates Extract Region features and identifies them for use in core and cavity tool definition. The layers for these region features are determined by mold_defaults settings: MW_PartingCoreSurfLayerName: CoreSurface MW_PartingCavitySurfLayerName: CavitySurface MW_PartingCoreSurfLayer: 27 MW_PartingCavitySurfLayer: 28



5-67



Core and Cavity

Check Geometry If this option is enabled, after you select sheets for the core or cavity, MoldWizard will run a geometry check and report invalid sheets before sewing.

Check Overlapping If this option is enabled, after you select sheets for the core or cavity, MoldWizard will check for overlapping geometry before sewing.

Create Cavity, Create Core The Create buttons automatically run checks if checking is enabled, sew the corresponding defined region to an extracted copy of the parting surfaces, activate trim when enabled, then temporarily display the tooling body.






WAVE relationships in the seed parts link the shrink body to the original part, and the parting body to the shrink body. When you create the Core and Cavity, the WAVE relationship is extended to the tooling, via linked tooling bodies and linked trim seed sheets. The core seed sheet is used as a target solid. The seed and the original parting surface are mutually trimmed and sewn together with the extracted core region. Thus the copy of the core seed in the tooling part is updated to reflect the parting and core region. A linked copy of the workpiece and the trim feature are in place in the seed assembly, but the trim feature is suppressed by expression. When you Create Core, all that MoldWizard needs to do is edit the trim expression and temporarily display the part. The cavity follows exactly the same process, except it uses a linked copy of the original parting sheet. MoldWizard provides the following dialog to return you to the parting part when you have finished examining the work piece.

IMPORTANT Note! When you reopen tooling projects from disk, default settings on your system may enable partial loading, to conserve memory usage. The Core_Cavity process will not be able to finish unless WAVE linked geometry is loaded. Activating MoldWizard before you open your tooling assembly is all that you need to do. Choosing Application → MoldWizard sets File → Options → Load Options to enable Load WAVE Data.


If you have WAVE, you can manually open WAVE linked parts in a previously opened assembly using the Assemblies WAVE options.



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Activity 5-5: Core and Cavity Regions

In this activity you will continue work on your mdp_cup1 project. NOTE


Step 1 Open your cup1 project.

Open cup1/mdp_cup1_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / cup1_2 / Step 2 Process the parting geometry and create core and cavity.

From the MoldWizard tool bar choose the Parting icon.

In the Parting Functions dialog enable the Auto Process option, as shown in the figure below.

Earlier we defined a parting curve in this project. Now that you know all the necessary steps to process geometry, you can appreciate what Auto Process does.


Auto Process is the default setting. We turned it off for this class, to help you to become familiar with using Parting Functions.

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Choose OK.

The Extract Regions dialog now appears, because you selected Auto Process.

Fit the view to see the parting surface.

The sum of core faces, 5, and cavity faces, 4, equals the total faces, 9.

Choose OK.


The Core & Cavity dialog appears.



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If the system can not determine cavity and core, a dialog will appear asking you to pick a seed face.

MoldWizard determines core and cavity by examining the difference in surface normal vectors of faces adjacent to the parting. The above dialog appears extremely rarely.

Choose Create Cavity.


In a few moments the Cavity tooling part, mdp_cup1_cavity, appears.


Let's take a moment to see what Reverse Normal does.

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Choose Reverse Normal.

Reverse Normal changes the trim direction of the parting sheet. If for any reason the system selects the wrong trim direction, you would correct it using the Reverse Normal button.

NOTE

Again, choose Reverse Normal in the View Parting Result dialog.

The above step is essential to achieve the original and correct parting trim direction.

Choose OK in the View Parting Result dialog.

Choose Create Core.


Choose OK.


Change the Displayed Part to mdp_cup1_top.

Fit the view.






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Activity 5-6: Diagnostics in the Extract Regions Dialog

You will discover how an unpatched hole is diagnosed by the Core & Cavity dialog, and explore tools to find problem geometry and make corrections. NOTE


Step 1 Open your outlet box project.

Open outlet/mdp_outlet_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / outlet_2 /

Step 2 Create Parting Surface.


From the MoldWizard tool bar choose the Parting icon.







A Warnings dialog appears:

Choose OK in the Warnings dialog.

Fit the view to see the parting surface.

Earlier, you patched the holes in the outlet face using Auto Patch. You deliberately removed one screw post hole from the system selection. You will now observe the effect of that missing patch.

Step 3 Define Core and Cavity regions.

From the Parting Functions dialog choose Extract Regions.



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Notice that the Cavity Faces plus the Core Faces add up to more than the Total Faces.

The Status line reports that 82 overlapping faces were found, zero faces were not used, and there are no void faces.


During the next action step, observe the part from above. These outer faces of the part are the Cavity Regions that will form the mold cavity.


Move the Cavity Face slider carefully from left to right and observe the cavity face regions as they highlight.

When the interior face of one of the corner mounting holes highlights, rotate the part to view the underside.

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Continue to move the Cavity Face slider to the right and observe how the detected cavity regions tend to spill over into the under (core) side of the part.

The highlighting faces on the under (core) side of the part are the overlapping faces MoldWizard detected. This overlap occurred because the hole that was deselected (not patched) during the Auto Patch procedure, allowed region detection to spill across the desired parting to the other side. Resetting the Cavity Face slider back to zero and moving the Core Face slider will demonstrate the same spill over effect from the core side.

Set the Display Mode back to Wireframe, Fit the view and select Cancel.

Step 4 Patch the remaining hole.

Choose the Tools icon.

Apply a Surface Patch on the lower face of the mounting screw post with no patch.


Step 5 Define Cavity and Core regions.


Choose Extract Regions.


This time the Status line reports Searching core/cavity boundaries..." and the face counts add up perfectly.



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Use the sliders to examine the core and cavity regions.

Choose OK to accept the region definitions.

How Does it Work? A region feature is a set of contiguous faces defined by a start face and a boundary. The region contains any face that can be reached" from the start face without crossing the boundary. Boundary faces are included in the region. A region definition is associative. If faces inside the boundary change, for example by the addition of a pad or boss, the Extract Region feature will update to include the new faces. MoldWizard constructs a region boundary based on faces adjacent to defined parting curves. TIP Be careful about the addition of holes. An unpatched hole will permit faces to be reached" that should have been outside the region, as you saw in the example part.

The Cavity and Core regions that you defined will be used together with parting faces and Wave links to create trimmed blocks for cavity and core tooling. Core and cavity region features in the parting part are a primary associative link between tooling and product model. Step 6 Create Cavity and Core Tooling Pieces.

If necessary, choose Parting.

Choose Cavity_Core.


The system should highlight the cavity region and one copy of the large planar parting face, and display a Select Sheets dialog.


This would be your opportunity to select other defined geometry for use in trimming the cavity work piece.

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Choose OK.

The system displays the parting result for your examination.

After examining the part, select OK to return your display to the parting part.

Choose Create Core.

When you have examined the part and it appears as shown below, choose OK to return your display to the parting part.



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Display mdp_outlet_top.


This concludes activity 5-6.






Activity 5-7: Defined Parting

A defined parting can be any face created via Enlarge Surface with the As Existing Surface" trimming option, or any face manually selected when you define parting sheets. You will now define Core and Cavity tooling using this sheet. It is important to add this approach to your repertoire of techniques for parts where a single face defines a contoured parting. NOTE


Step 1 Open your case6 project.

Open case6/mdp_case6_top.

If needed, a staged assembly for this activity is in: .../ moldwizd / case6_2 /



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Step 2 Create cavity and core regions.

Choose Parting Extract Regions.

The technique you will use is most powerful with parts where a single face can be enlarged to form a useful parting sheet. It is interesting to note that this part currently has no defined parting lines, nor any defined parting sheets. Use the sliders to that the system has correctly identified the exterior of the case as cavity and the interior as core.

Choose OK to create the region features.

Step 3 Create the Cavity and Core.

Choose Cavity_Core from the Parting functions dialog.


Notice that MoldWizard appears to have identified the sheet you created with enlarge surface. In fact, when you enabled As Existing Surface, the system made copies of the sheet, one each for cavity and core. It is the extracted copy in layer 28 that you see now. (The layer is controlled in the default file.)


Examine cavity tooling work piece.


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Choose OK to return to the parting part.





Choose Create Core.

Notice in the Work Layer toolbar that you are now examining objects in layer 27.


Examine core tooling work piece.

Choose OK to return to the Parting Functions dialog.

Step 4 Save your work and close the currently open assembly.

From the Menu Bar choose File Close Save All and Close. This concludes Activity 5-7.





Edit Parting Functions MoldWizard is able to handle most changes to the product model even after the Core and Cavity have been defined. The approach to updating your mold will depend on the nature and complexity of the change:

Internal Change: Any change of these types will propagate to mold design automatically:

the addition of boss, rib, or pocket

the relocation of such features

Topology/Parting Change: This includes:

adding or removing holes / windows

adding or removing feature(s) that affect parting

New model This is often the case when the customer is using another CAD system to design their parts.






Suppress Parting and Update Parting The Suppress Parting and Update Parting features are used to edit a mold design after the cavity & core have been extracted and trimmed. The goal is to maintain associativity to minimize any rework that may be required.

Procedure for Part Model Topology Changes or New Model

Suppress Parting

Assure that the parting file is the work part

Choose Suppress Parting to suppress the cavity & core region features and trim features

If necessary, use Swap Model

Recreate parting lines and transition objects

Edit the Parting Surfaces

Patch new holes

Delete any unneeded patch and parting sheets

Edit transition points along the parting loop

Create new parting surfaces as needed

Update Parting

Choose Update Parting to unsuppress features and update regions and bodies. TIP In the current release, the Swap Model function removes parameters from all parting lines and parting surfaces. For this reason it is important to determine if it will be more efficient to modify the original product model or swap model, for each part design change.



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Activity 5-8: Topology Change to Product Model In this activity we will simulate a customer request to change the part so that the outlet box can be used with conduit and to add openings for ground fault condition interrupter (GFCI) buttons. Step 1 Open your outlet box project.

Open the product model mdp_outlet.

Open outlet/mdp_outlet_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / outlet_3 / Step 2 Suppress parting on your mold.


Choose Suppress Parting.

Step 3 Create a datum plane to use for a pocket.

Change your displayed part to mdp_outlet.

Make the datum planes visible by making layer 61 the Work Layer.






À Á

Create a datum plane through the near edge (in TFR-TRI view) and parallel to the center plane as shown above. Hint: Insert Form Feature Datum Plane. Select the center plane and then the edge. Use zero degree angle.

Step 4 Add a pocket for conduit connection.

Choose Insert Form Feature Pocket.

Choose Rectangular.

Select the newly created datum plane as the placement face . . . À

Choose Flip Default Side.

À


Á

Select the front edge as the horizontal reference . . Á



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Enter the values shown above.

Choose OK.

Use the Line onto Line positioning tool to position the pocket such that the vertical center line is aligned with the center datum and the horizontal center line is aligned to the bottom edge.






NOTE

If the Edit During Update dialog appears, dismiss it using the Accept Remaining icon.

Notice that the error occurred in the parting part. This demonstrates why we recommend suppressing the parting! With the parting suppressed, the failure of the planar parting to update will not cause further problems.

Step 5 Relocate the screw hole.

Choose Edit Feature Positioning, select the center hole from the graphics screen, and choose OK.



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Choose Edit Dimension Value and select the dimension shown (dimension should be p68) . . À

À

Á

Enter 1.625.

Choose OK four times, until the part updates.

The hole should move to the location indicated . . . Á






Step 6 Duplicate the screw hole using Mirror Feature.

Choose Insert Feature Operation Instance. Choose Mirror Feature.


Select the relocated hole from the graphics screen.



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Choose the Datum Plane selection step icon on the dialog.

Select the center datum plane from the graphics screen.

Choose OK.

Choose Cancel to dismiss the Instance dialog.

Step 7 Add pockets for the GFCI buttons.

Choose Insert Form Feature Pocket.

Choose Rectangular.

Select the top face of the outlet for the Placement Face and the shorter center datum for the Horizontal Reference.

Enter the Values shown.

Choose OK.






À Á

Choose a horizontal dimension.

Select the datum shown À as a horizontal reference.

Position the long center line on the datum . . . À Hint: Use Line onto Line.

Position the short center line 0.350 from the datum . . . Á Hint: Use perpendicular.

Use Mirror Feature to duplicate the pocket using the same technique as shown above.

Make layer 1 the Work Layer and layer 61 Invisible.





Step 8 Create new Patch Surfaces for the newly created holes.


Change your displayed part back to the parting file by choosing the Parting icon.

Choose the Tools icon.

Make the product model visible by making layer 1 Selectable. Make the patch sheets visible by making layer 27 Selectable. Turn shading on. Inspect the holes in the part. Notice the original screw hole patch surface relocated to the new position.

Choose Auto Hole Patch and deselect the five loops for holes already patched by holding your shift key down while selecting the patched holes. Three loops will remain selected.

Choose Auto Patch to create the surfaces. Choose Back to dismiss the dialog.

Step 9 Correct the parting lines by adding the new edges created by the conduit pocket.

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Choose the Parting icon then choose Parting Lines.





Choose Edit Parting Lines.

open end

À

À

open end

Add the six bold edges shown above to the parting.

Choose Add Transition Points then select the two end points shown above . . À

Choose Back to return to the Parting Lines dialog, and then choose OK.



5-95


Step 10 Replace the parting surfaces.

Choose Parting Surfaces from the Parting dialog.

Choose Delete Parting Surfaces Õ Delete All.

Choose OK.







NOTE

Use the bounded plane option to create the first surface as shown below.

Use U and V factors large enough to be certain that your plane will trim the work piece.

1

2

Use the extrude option to create the second surface.

Choose Back.

Notice that you did not sew the surfaces. Observe the status line as you perform the next action. The system has the intelligence to realize that a sew operation is needed. Information will display very briefly as a sew is performed.

Choose Update Parting.

The status line should indicate that the update is occurring. The screen might flicker during update; this is normal. The core and cavity parts will very briefly display.

Change your displayed part to the core or the cavity and confirm that the mold updated as desired.






This activity demonstrated the capability of updating your mold to inherit the new features introduced to the product model. Since associativity to the sewn parting surface was maintained all downstream features should update accordingly This concludes Activity 5-8.






Compare and Swap Model As stated earlier, a mold designer will frequently be given a completely new model that represents a customers changes to a part for which a mold is already being developed. MoldWizard provides tools to compare the before and after condition of the product model and then exchange the new part for the old one.



5-99







Activity 5-9: Compare and Swap Step 1 Create a mold project for mdp_handle.

First Part

.../handle/mdp_handle

Units

default (Inch)

Proj Name

default (mdp_handle)

Mold Csys

default


1.006

Work Piece

default

Layout

Auto Center

Step 2 Define the parting lines.


Enable the Auto Process option.




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From the Search Parting Lines dialog choose Auto Patch Auto Patch to patch up the hole on top of the product model.

Choose Back then OK to accept the parting lines.

From the Parting Lines dialog choose Auto Transition Objects.






Choose Convert Transit Objects from the Auto Transition Objects dialog.

Choose OK in Auto Transition Objects.

Choose OK in the Parting Lines dialog.

Step 3 Create the Parting Surfaces.

From the Create Parting Surfaces dialog, choose Create Parting Surfaces.



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Use Bounded Plane to create the first (largest) parting surface as shown below. The trim vectors should be parallel to the Y axis.

Use Bounded Plane on the next string as well. Use vectors parallel to the existing sheets edges. Hint: You may need to choose Flip Trimmed Sheet.

Choose OK.





MoldWizard should create your auto-swept surfaces to complete the parting surfaces as shown.

Step 4 Create the Cavity and Core.

From the Create Parting Surfaces dialog choose Auto Cavity_Core.

Auto Core_Cavity automatically sews your parting surfaces, extract regions, then splits your core and cavity models for you. This is a useful option when working with simple parts.



5-105



Step 5 Save your project.

Change your displayed part to mdp_handle_top.

From Main menu bar choose File Save All.

Now we will simulate receiving a newer version of the customers part. We will first compare the before and after conditions so we can understand the changes and determine the impact (if any) to our mold design. Step 6 Compare the new handle with the existing handle.

From the MoldWizard tool bar choose Parting.

Choose Compare Product Models.






From the Open File dialog choose mdp_new_handle

MoldWizard opens a three-view layout and overlays the new and original handles.

Enable shading for both the new and original models by swtting Shading to ON . . . À

Choose Apply . . . Á

À À


Á



5-107


Use the translucency slide bars to view the models and fully understand the changes that occurred.

We can see from the display that the following changes occurred:

handle has contours added to the grip area.

the trigger cut-out has a new shape.

the opening on the side has changed shape.

a new blend has been added to the top edge.

Step 7 Swap the handle for the new handle.

Choose Back the exit the Model Comparison dialog.

From the Parting Functions dialog choose Swap Product Model.

Choose the mdp_new_handle from the Open Part File dialog.

MoldWizard retrieves the new model and adds it to the product subassembly", creates links to the shrink part and the parting part, and suppresses the core and cavity trim.

Step 8 Remove the original parting and patching surfaces impacted by the change.


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Make sure that layers 26, 27 and 28 are selectable and all other layers are invisible.





Depending on the severity of the changes, you could choose to delete all parting and patching surfaces and create new surfaces in their place. However, this is not necessary. You can choose to replace only those surfaces impacted by the changed model.

Choose MoldWizard Tools.

Choose Parting/Patch Delete.

À

Choose Delete Patch Surface . . . À

Á

Select the patch sheet . . Á

Choose OK confirming the delete.





Â

Choose Delete Parting Surface . . Â

Ã

Choose Delete Selection . . . Ã

Ä Ä


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Select the two sheets illustrated above . . Ä





Choose OK confirming the Delete.

Choose Back, and Cancel the Tools dialog.

Step 9 Re-establish Parting Lines and Patch Surfaces.

Choose the Parting icon from the MoldWizard toolbar.

Choose Parting Lines Auto Search Parting Lines Apply.

Choose Auto Patch Auto Patch.

Choose Back OK Auto Transition Objects Convert Transit Objects, and then OK twice.

Step 10 Create the missing Parting Surfaces

From the Parting Functions dialog choose Parting Surfaces Edit Parting Surfaces.

From the graphics screen select a curve from the outside string.

Select Here

Use Bounded Plane option to create the surface.

Select a curve from the trigger cut out area.





Choose Auto Surface and Edit Primary Edges.

Select the two edges illustrated below . . . ÀÁ

Á À


Choose OK.

Cancel the Curve/Point Selection dialog.





Step 11 Complete the swap by updating the parting.


Choose Update Parting from the Parting Functions dialog.

The system takes several moments to recreate various features. You may now change your displayed part to inspect the new core and cavity.

Step 12 Save All and Close. This concludes Activity 5-9.



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SUMMARY

MoldWizard provides useful tools for creating parting geometry. You learned how to define parting curves and edges from existing geometry, and how to use the system to subdivide faces at isocline curves to create a natural" parting. You learned a method to incorporate your own sheets into the associative parting used by MoldWizard. You used the MoldWizard system to create region features for core and cavity, then created associative tooling from each region. In this lesson you:

Constructed parting curves.

Used Traverse Loop to select appropriate parting curves from system created potential parting curves.

Identified transition curves and points.

Constructed parting surfaces.

Extracted core and cavity regions.

Used Enlarge Surface to create a simple parting.

Created linked core and cavity models.

Compared an update model to one used in a tooling assembly

Substituted an updated model in a tooling assembly.





Mold Base


Mold Base Lesson 6

PURPOSE

OBJECTIVES

In this lesson you will select and add a standard mold base to a mold project assembly.


Use the Mold Base Management dialog to add a Standard Mold Base to a two cavity mold insert assembly.

This lesson includes a review section, within which you will practice family mold, layout, and custom parting with enlarged surfaces. Additionally, you will prepare a tooling assembly for the future addition of slides and lifters.

This lesson contains the following activity: Activity

Page

6-1 Adding A Mold Base . . . . . . . . . . . . . . . . . . . . . . . . 6-8



6-1

Mold Base


Mold Base Management MoldWizard includes several standard mold base catalogs: Catalog

Metric

Inches

X

X

DME DME_Interchangeable

X

Futaba

X

Hasco

X

Hasco_E

X

Hasco_Interchangeable

X

LKM

X

Omni

X X

Universal

X

X

Select a moldbase that will accommodate your mold insert from one of these catalogs. to include allowances for cooling lines, runner systems, etc. The Universal moldbase is for designers who need a moldbase plate stack configuration that is different from any of the standard moldbase configurations. This is usually done to provide mechanisms for moving parts.

6-2




Mold Base


Selecting the Mold Base icon will open the Mold Base Management dialog:



6-3

Mold Base


Catalog The Catalog list À allows you to select the preferred mold base supplier. The content of this pull down is controlled by a spreadsheet that can be edited using the Edit File button. NOTE

Some catalogs are available in only one of Inch or Metric Units.

À

Á

Type The Type list Á is used to specify a particular type of standard mold base offered by the supplier, for example 2 or 3 plate Mold. This information is also controlled by the file.

6-4




Mold Base

Bitmap MoldWizard will display a schematic diagram Â of the standard mold base for the selected catalog supplier and type. The diagram is taken from a standard bitmap file. You can create your own bitmaps for custom Mold Bases.

Â

Ã Ä

Mold Base Index List This list offers the XY dimensions Ã available for the selected standard mold base. The system will determine which choice best suits your layout and offer that choice as the default, based on Layout Information Ä stored when you use Layout.



6-5


Mold Base


Edit File Edit File Å will open the MoldWizard spreadsheet file where the selected standard mold base is ed. This edits Mold Base menu choices. Edit Data Base Edit Data Base Æ will edit the MoldWizard spreadsheet file where components of the selected standard mold base are defined.

Å Æ Ç È

Rotate Mold Base Rotate Mold Base Ç is used to rotate the entire mold base assembly 90 degrees while keeping the insert layout stationary. Edit Component Edit Component È is used to modify a parameter of a component of a mold base after the mold base has been added to your assembly.

6-6




Mold Base


Customization As an example, to customize the Universal mold base, you would

Save a copy of the seed assembly

Modify the assembly or components to your needs

Add new parameters and choices to the Data Base

Edit unwanted or modified choices in the database

Define new pull down Lists as desired (see below)

Include the new part in your menus via the File

Expression List The mold base Expression List À contains all mold base parameters that may be edited. The expression that is highlighted in the list will appear for editing in the Expression Edit Window Á immediately below.

À

Á Â Standard Component Size Lists The list boxes found in the bottom portion of the dialog Â allow easy selection of standard sizes from drop down lists.



6-7


Mold Base

Activity 6-1: Adding A Mold Base

In the following project, you will review earlier lessons. Very few details are given for familiar steps.

À Â Ã

Á

Ä

6-8

À

Upper Case - mdp_mcu

Á

Lower Case - mdp_mcl

Â

Snap (one on each side)

Ã

Snap Seat (one on each side)

Ä

Cord Opening




Mold Base

During this Activity you will work with two pieces of a 3 button mouse assembly to produce a two cavity family mold with examples of slide and lifter techniques. The parts are greatly simplified to permit faster load times and faster progress. Slides and lifters will be added in the standard parts lesson.

À

Á Mold Insert Layout - Upper and Lower Mouse Case

NOTE

À

Upper Case Insert

Á

Lower Case Insert


Step 1 Open your mouse project.

Open .../mouse/mouse_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / mouse_3 / Step 2 Create a Mold Tooling Insert.

Set the Work Piece size: Type: X_length . . . . . . . . . . . . Y_length . . . . . . . . . . . . Z_down . . . . . . . . . . . . Z_up . . . . . . . . . . . . . . .


175.0 125.0 56 56


6-9


Mold Base


Replace View to TFR-TRI.

Step 3 Create a single face contour parting.

Choose MoldWizard Tools Enlarge Surface.

Set the Work Layer to 2, and make layer 20 Selectable.

Select the narrow lip face of the part . . . Â

Â

6-10




Mold Base

Enable Cut to Boundary, and be sure the As Existing Surface toggle is enabled (the default condition).

Rotate the part if necessary and use the insert block in layer 20 as a visual guide to make the surface larger than the insert block: enlarge at least 80% in U and 65% in V.

Choose OK to accept the default trim boundary . . . Ã and default trim options.

Ã

Step 4 Adjust layer options.

In the Layer Settings dialog, make 1 the Work Layer, and all others Invisible.

Notice that there is nothing in layer 2, the previous Work Layer. The option As Existing Surface tells the system to treat the face created as a core and cavity pair. The original is placed in layer 255, MW_HideObjectLayer. Extracted copies are placed in layers 27 and 28, MW_PartingCoreSurfLayer and MW_PartingCavitySurfLayer respectively. Step 5 Prepare core and cavity regions.


Enable Auto Process.



6-11


Mold Base


Choose Extract Regions.

that you have 24 total faces, 4 in the Cavity and 20 in the Core, then choose OK.

Step 6 Create, examine, and accept both cavity and core inserts. Notice that the core part contains undercut areas at the Snaps".

Step 7 Create a slide head. Note that mouse_mdp_mcu_core is both the work and displayed part. In this step, you will create a slide head in this core insert file.

Choose the MoldWizard Tools icon.

Make 10 the Work Layer.

If necessary, set the Display Mode to Wireframe.

Zoom in on the area shown in the figure below.

Create Box using an Allowance of 6.5 millimeters, and the two shaded faces shown below.

ÄÄÄÄÄ ÄÄÄÄÄÄ ÄÄÄÄÄ ÄÄÄÄÄ ÄÄÄÄÄÄ ÄÄÄÄÄÄ ÄÄÄÄÄ ÄÄÄÄÄÄ 6-12




Mold Base

Use MoldWizard Surface Split to trim the block using the five faces shown below.

: The Vector Arrow points toward the side you want to remove.

À

Ã

Á

ÄÄÄÄ ÄÄÄÄ ÄÄÄÄ ÄÄÄÄ

Â

Ä Face

Split with...

À

Top

Parting sheet

Á

Bottom

Lip of snap

Â

Side adjacent to product

Outer face of snap

Ã

Left Side

Left side of snap

Ä

Right Side

Right side of snap

The desired result is illustrated below.



6-13


Mold Base


Use Edit → Object Display to set the partial shading attribute to YES for the small block just created.

Standard parts, including slides and lifters, are partially shaded. This solid body is partially shaded because it will eventually become part of a slide assembly. Step 8 OPTIONAL: If time permits, create a slide head on the opposite side of the part. Step 9 Save your work.

Make mouse_top the displayed and work part.


TIP It is a good idea to save your work before modifying the project by adding other products.

Step 10 Create a family mold by adding the lower case.

6-14

Use the Load Product icon to add mdp_mcl (mouse case lower) to your assembly.

Rotate the WCS 180° about either YC axis (plus or minus).

Set the Mold CSYS to the Current WCS with the Lock Z Value checkmarked ON (the default Mold CSYS settings).




Mold Base

If the WCS is correct the lower case will flip over", but will still lie on top of" the upper case, as shown below. You will correct the position in just a moment, using layout.

Enter Shrinkage, Uniform Scale factor 1.005



6-15


Mold Base


Set the Work Piece size, using the previous values: Type: X_length . . . . . . . . . . . . Y_length . . . . . . . . . . . . Z_down . . . . . . . . . . . . Z_up . . . . . . . . . . . . . . .

175.0 125.0 56 56

When you intend to machine inserts with one or more dimensions the same, you might create several work pieces to determine the size needed. You can easily edit various work pieces to the dimensions you determine. We supplied values based on our experience in creating the activity.

Use Layout → Transform → From Point to Point to create the arrangement shown below, rounded ends facing together:

Hint: as you transform, you can visually distinguish the end points of work piece edges easily. Notice that the upper case is already split into core and cavity, and the lower case is not.

6-16

Use Auto Center to center the inserts about the WCS.

Cancel the Layout dialog.




Mold Base

Step 11 Create one patch surface at the cord opening. Although edges could be extruded to create a parting with a lump" in it for the cord opening, Product Design Advisor showed us that the walls of the opening have no draft. If we were to extrude the edges the resulting contour would be too susceptible to wear or damage. For this example we will simply shut off the opening and accept small undrafted faces in the core.


Choose Edge Patch.

Using the illustration below as a guide, select the top of the left vertical edge . . . . À

Choose Accept or Next Path as required to select the arc and opposite vertical edge.

Á

À Â

Â

After the opposite vertical edge Á is accepted, the Traverse Loop function will highlight one of the lower edges . . Â When this occurs:

Choose Close Loop.

The outer face surrounding the opening will highlight and the status line will read: Found 1 faces to patch up.



6-17


Mold Base


Choose OK to create the patch . . . . Ã

Ã

Step 12 Create a single contour parting face.

6-18


Choose Enlarge Surface.

Select the face indicated in the illustration below.

Using the insert block for reference, enlarge about 70% in U and V.




Mold Base

Enable Cut to Boundary.

The desired boundary for this operation is the outer perimeter of the highlighted face edges. NOTE

The inner perimeter edges and small edges inside the cord opening need to be edited out of the boundary definition. The following action items will demonstrate a simple way to define the required boundary.

NOTE

Choose Edit Boundary.

Deselect All the highlighted edges by dragging a rectangle around the edges with a shift key depressed.

Select the 6 edges of the outer perimeter.

Don't forget the small corner radii.

Choose OK when your edits are complete.

Choose OK to create the enlarged and trimmed sheet.

Make/ layer 1 the Work Layer, and all others Invisible.



6-19


Mold Base


Step 13 Create tooling inserts.

Choose Parting.

Set Auto Process.

Extract Regions for core and cavity as before. There should be 34 faces, 15 in the cavity and 19 in the core.

Create Cavity.

Create Core.

Notice that the core insert contains a small undercut in the Snap area . . À This will be addressed in the next lesson by adding a lifter.

À

6-20




Mold Base




Step 15 Add a mold base.

Choose the Mold Base icon.

Choosing Mold Base automatically changes the displayed part to mouse_top. Because the parting is contoured we make a mental note that we will eventually have to create draft or clearance where insert edges depart from the parting plane.

Choose the DME Catalog . . À

Choose Type 2B . . . . Á

À

Á

Choose the BP_h pull down and select 56 from the list . . Â

Ã Â

Choose the AP_h pull down Ã and select 56 . . Ã



6-21

Mold Base


Index size 4545 is automatically selected . . . Ä because you earlier used the Layout dialog. Using Layout saves Layout Information . . Å

Ä

Å

TIP An important function of Layout is to save information about the size of the work piece layout. This enables automatic mold base index selection.

6-22




Mold Base

Choose Offset_Fix . . . Æ

Type .051 in the input window . . Ç

Press Enter.


Æ Ç When you press Enter, the value you typed will appear in the parameter list . . . È

Choose Offset_Move . . É

Enter .051 in the input window . . . Ê

È É Ê



6-23

Mold Base


Choose OK to accept the remaining defaults and add the moldbase.

Adjust the view and examine the mold base.

Step 16 Save your work. You will use this assembly again in the lesson on standard parts.

Choose File → Close → Save All and Close . This concludes Activity 6-1.

6-24




Mold Base

ÏÏÏ ÏÏÏ 6 ÏÏÏ ÏÏÏ SUMMARY

This lesson introduced the Mold Base Management dialog and the process MoldWizard uses to add a standard mold base to an existing mold insert layout. The importance of reviewing and resolving dimensional differences in the mold base/insert assembly was mentioned. This lesson also provided a review on core & cavity extraction and the process of laying out a two cavity production mold. In this lesson you:

Reviewed previous lessons by building the mouse assembly.

Prepared the mouse shrink part for the future addition of slides and lifters.

Used the Mold Base Management dialog box to add a Standard Mold Base to a two cavity mold insert assembly.



6-25

Mold Base


(This Page Intentionally Left Blank)

6-26




Standard Parts

Standard Parts Lesson 7

PURPOSE

OBJECTIVES

You will use the Standard Part Management dialog to add standard parts to a mold base assembly, including Ejectors and Sliders and Lifters. You will practice Pocket Creation.



Select standard parts from a standard parts catalog.

Edit standard part parameters and define locating points.

Add standard parts to a mold base assembly.

Create pockets to accommodate the added standard parts.

Add sliders and lifters to an assembly.


Page

7-1 Adding Ejector Pins and a Sprue Bushing . . . . . . 7-15 7-2 Post Processing and Pockets . . . . . . . . . . . . . . . . . . 7-33 7-3 Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45



7-1

Standard Parts

Standard Parts Overview


Several MoldWizard functions are used for the placement and management of standard parts," or hardware needed in a tooling assembly.

7-2




Standard Parts

Standard Part Management Standard mold components are selected from a catalog and positioned within the tooling assembly. Standard parts can apply to the mold generally, e.g. locating ring & sprue bushing, or to individual mold inserts, e.g. ejector pins & ejector sleeves. Some standard parts are automatically located by MoldWizard, and others require a defined locating point.

Ejector Pin Postprocessing Ejector Pins are selected and positioned using the Standard Part Management dialog. The Ejector Pin dialog provides postprocessing tools to define the close fit distance" and to optionally trim ejectors to part contours.

Slider and Lifter The Slider Lifter dialog provides a specialized set of standard parts, slider and lifter subassemblies.

Mold Trim This utility automates commonly needed WAVE linking and feature modeling tasks to trim a standard part to the core or cavity trim sheet.

Pocket Creation Once standard parts are selected and positioned within the mold assembly, pockets, voids, threaded holes, etc. must be created to receive these added parts. Pocket Creation is also used with Gates, Runners, and Cooling channels.



7-3


Standard Parts

Other Standard Part Library Functions Several important functions make Standard Part style libraries available:


7-4

Work Piece

Sub Inserts

Cooling

Electrodes




Standard Parts

Standard Part Management Catalog Tab


À

Á

Catalog The Catalog pull down menu À allows you to select a standard parts catalog from a list of standard mold part suppliers including: Hasco, DME, Futaba (Metric only) and Omni (Inch only). An additional choice, Component_Set, allows adding sub components with multiple instances in patterns, such as locating screws and springs Additionally, the catalog list contains a Yates hydraulic cylinder (Inch only). Only catalog names with corresponding units to your project will appear. It is important to consider units before beginning a project, with forethought regarding the Mold Base and Standard Parts catalog you want to use. Parts List Window The window immediately below the Catalog window Á lists parts available from the specified supplier. The number and type of parts listed can be filtered by using the Classify list described next.



7-5

Standard Parts

Classification The Classification pull down menu Â provides a filter to narrow the list of standard parts that appear in the Parts List Window described previously. The default setting of All Standards will include all standard parts offered by the supplier. Other choices under Classify that will narrow this list may include: Locating Ring and Sprue, Ejector Pin, Locks, Screw, and Other.


Â

Ã Ä

Standard Part Name The Standard Part Name field Ã displays the default part file name for a new instance of the selected standard part. If the part was added previously, the name will be appended with a unique number. This filename may be edited to any valid name by editing in the input window . . . Ã Flip Direction Flip Direction Ä allows you to flip the normal" direction for a standard part that is positioned on a plane. The part will move to the opposite side of the placement plane.

7-6




Standard Parts

Parent The Parent pull down menu Å allows you to specify the parent component for added standard part. If the parent you want is not in the list, make it the work part before you access Standard Parts. The work part is always on the list.


Å Æ

Ç

Position The Position menu Æ allows you to specify the method to be used for positioning a standard part: NULL: . . . . . . Origin will be the absolute (0,0,0) of the assembly tree WCS: . . . . . . Origin will be the current WCS (0,0,0) POINT: . . . . . Uses X-Y plane with a selected point as the origin PLANE: . . . . . Select a planar face as X-Y plane, then select an origin point MATE: . . . . . . Add the part at any selected point, then position it with mating True / False / Both This set of radio buttons Ç controls the reference set to display for standard parts you are adding. True displays the standard part geometry, False displays the pocket cutting geometry, and Both displays both sets of bodies at once.



7-7

Standard Parts

Add/Modify When an existing standard part is selected in the graphics screen, the Add/Modify toggles will be made available . . . È

ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ È

Add will add another standard part that is identical to the selected part. Modify is used to edit the selected part. Standard Parameter Lists The most common dimensional features of the selected part are listed in the bottom portion of the Catalog tab. Features available here are pre-defined standard sizes from the supplier. For more detailed editing choices, choose the Dimension tab.

7-8




Standard Parts

Dimension Tab

À


Bitmap An illustration À depicts the selected standard part and key dimensions.



7-9

Standard Parts

Parameter List A window Á lists all editable values for the selected part. The parameter that is highlighted in the list appears for editing in the Edit Window Â.


Á

Â

7-10




Standard Parts

Lock/Unlock The main purpose of parameter-locking Ã is to preserve values when a large change is made to a mold design in progress, such as a mold base size. Locked parameters, such as plate thicknesses or screw positions, will not change to the defaults for the new mold base size.

Ã


A locked dimension can only be edited manually. There is a "*" before a dimension name when it is locked . . Ä

Ä

Å

Æ

When the selected dimension is locked, the left button will read Unlock . . . . Å If a dimension is locked, it will be grayed out Ç on the Catalog Tab. s cannot change it from an Options list or a slider bar.

Ç Unlock All Unlock All Æ is, as the name implies, a rapid method to unlock all locked parameters for the selected standard part.



7-11

Standard Parts

Operation Tab Edit File / Data Base These buttons ÀÁ will open a MoldWizard spreadsheet file for the standard part library. The spreadsheet controls what parts appear in the menu, classifications available, bitmaps, parameters in the list box, and pull down parameter lists. The Data Base spreadsheet can edit parameters, attributes, and other data related to the selected standard part.


À

Á

Â Ã

Remove Component Remove Component Â removes selected standard parts from the assembly.

Reposition Reposition Ã allows you to reposition selected standard parts within the assembly via translations, rotations, and point to point movements. TIP If you reposition ejector pins, or any standard parts which have

relationships with the moldbase, such as locating rings and lifters, don't move the Z value, because the Z level distances are controlled by MoldWizard relationships.

7-12




Standard Parts

TIPS When you add a standard part, it is recommended to set the Partially Shaded option as the Display Mode. MoldWizard Standard Parts have the parĆ tially shaded attribute set. You need to set Assemblies_AllowInterPart: yes in the ug_metric.def or ug_english.def file.


Make sure not to turn on Delay Interpart Updates default in UG Assemblies module section of the defaults files. If the system is in the Assembly Parts List or the Drafting application, switch to the Modeling apĆ plication. Clearance values ("clr" in expression name) default to zero. If clearance is desired, look for and edit these expressions. Clearance expressions affect the corresponding pocket creation body.



7-13

Standard Parts

Tip for Opening Large MoldWizard Assemblies


From this point in the class onwards, tooling assemblies you open may have many . On Windows systems, you can avoid having to search a scrolling list for the top part. In the Windows Open Part File dialog, enter File name *top.prt" (without quotes) and press Enter. The file list will be filtered to only the top level part, as shown above.

7-14




Standard Parts

Activity 7-1: Adding Ejector Pins and a Sprue Bushing In this activity you will add Ejector Pins and a Sprue Bushing to the two cavity tray mold assembly. One Ejector Pin exists for each cavity . . À


À

À

Each cavity requires four Ejector Pins. As these instance specific pins are created, they will automatically appear in all instances of the mold cavity.

NOTE


Step 1 Open your mdp_tray_top tooling assembly. If needed, a staged assembly for this activity is in: ... / moldwizd / tray_2 /



7-15

Standard Parts

Step 2 Set the display to a TOP view. Step 3 Add three Ejector Pins.


Select the Standard Parts icon:

that the Catalog is Hasco.

Change the Classification field to Ejector Pins.

The work part changes from the tray_top assembly to the parent tray_prod part and one cavity highlights.

Zoom In on the highlighted cavity:

Á

7-16

Select the existing Z41 pin from the screen . . Á




Standard Parts

Choose Add to create new instances of the same part . . . Â


Ã

Â

Set the Position Method to Point . . . Ã

Choose Apply.



7-17

Standard Parts

The Point Constructor dialog displays to aid in locating the ejector pin.


7-18

Choose the Arc/Ellipse/Sphere Center icon.

In the graphics screen, select the arc edge shown below:

Cancel the Point Constructor dialog.




Standard Parts

The Standard Part Management dialog displays. NOTE

Each of the three new Ejector Pins must be moved 5mm in the Y direction. One pin also needs adjustment in the X direction. A drawing is provided. You will adjust each pin as you add it.

Choose the Operations tab.

Refer to the drawing below for positioning information:


1.000

5.000

NOTE

The 1.000 offset in X applies only on the side adjacent to the sharp corners of the tray.

Zoom in to observe an target ejector pin and its location.

The most recently added ejector pin should still be selected. Use screen selection to pick it if necessary.



7-19

Standard Parts

In the Standard Part Management dialog, select the Reposition Part button. The Reposition dialog opens.

Enter 5.0 in the Y entry field to locate the top ejector pin, and select OK. Use -5.0 when appropriate.

Enter plus or minus 1.000, as appropriate, in the X window for pins located near the back (sharp corners) of the tray.


The ejector pin moves to the correct location and the Standard Part Management dialog reappears.

7-20

Return to the Catalog tab.

that an ejector pin is still selected, and that the Add option is still active.




Standard Parts

Add two more Ejector Pins by first selecting, then confirming the two arc edges shown below:


After all three pins have been added and reĆpositioned, Cancel the Standard Part Management dialog.

Use Assembly Navigator to make tray_top the work part (if necessary).

Go to a Trimetric view by clicking MB3 then choosing Replace View TFR-TRI from the pop-up menu.



7-21

Standard Parts

Partially Shade the view by clicking MB3 then choosing Display Mode Partially Shaded.

Standard part bodies have their Partially Shaded" attribute set to Yes." This enables you to easily visualize standard parts placement relative to a wire frame mold base assembly.


NOTE

Examine the mold assembly and the new instances of the trimmed ejector pin that have been placed.

If the pins required different trim, we could not have used the instancing method. A new pin component is required for at least one instance of every unique trim configuration.

Step 4 Add a Sprue Bushing.

Choose the Standard Parts icon.

From the HASCO Catalog, choose Classification Sprue . . À

Locate and select Z512 (Sprue Bushing) . . Á

Edit the parameters. Refer to the illustration if necessary. Sprue Type . . d2 . . . . . . . . . . d1 . . . . . . . . . . l ............ sr . . . . . . . . . . .

7-22

Sphere . . . . . . 18 . . . . . . . . . . 4 ........... 66 . . . . . . . . . . 15.5 . . . . . . . .

Â Ã Ä Å Æ

Choose Apply . . Ç




Standard Parts

À Á


Ã Ä Å Æ

Â

Ç



7-23

Standard Parts

The sprue bushing is automatically aligned with the top center of the moldbase. The standard length provided may or may not be correct for the assembly. We chose a centering ring that is recessed 4mm below the top of the upper plate. The lower end of the standard length sprue bushing extends 1mm into the moving half. You could this information, optionally, using AnalysisĂÕĂDistance.


Choose the Operation tab.

The sprue bushing should still be selected.

Choose Reposition.

Enter -4.000 in Z, and then choose OK.

The bushing is now correctly aligned with the centering ring; however, the other end now extends into the moving half by 5.0mm.

7-24




Standard Parts

Choose the Dimension tab . . . À

Select the line for l in the list . . Á

À


Á

Â

Edit the value of l to 61.0 . . . Â Hint: Do not forget to press Enter.

Choose OK. This concludes Activity 7-1.



7-25

Standard Parts

Ejector Pin Post Processing The Ejector Pins initially added to a mold assembly will be of a standard length and shape. Ejector Pin Post Processing refers to the steps that are taken to modify a pin's standard length and shape to match the specific size and shape of an individual mold and product part design. Selecting the Ejector Pin icon will open the Eject Pin Post Processing dialog:


Select Trim Methods

Display Options

Trim Surfaces

Fit Distance

Trim Methods MoldWizard offers two ejector pin trim options, and the ability to Untrim. Display Options Display options control the display of the ejector pins and their corresponding pocket bodies. Trim Surfaces Controls the surface to which ejector pins are trimmed. Fit Distance Fit distance or land refers to the length of tight tolerance fit that is to be held at the tip of the ejector pin where it erupts from the core face.

7-26




Standard Parts

Trim Methods Adjust Length This trim method adjusts the length of the ejector pin to the highest Z level of the pocket opening on the surface of the core body. Note how this trim method will leave a pronounced knockout mark or indentation in the molded part.

ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ À ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ Â ÍÍÍÍÍÍÍÍÍÍ Ã ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ Á ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ

À

Cavity Steel

Á

Core Steel

Â

Pocket where plastic will flow

Ã

Highest Z level of pocket opening




7-27

Standard Parts

Sheet Trim This trim method contours the end of the ejector pin to match the core surface. Note how this trim method will not leave a pronounced knockout mark or indentation in the molded part.

ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ À ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ Â ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ Á ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍÍÍÍÍÍÍÍÍ


À

Cavity Steel

Á

Core Steel

Â

Pocket where plastic will flow

Untrim This option is used to remove the trim from an ejector pin.

Display Options The Display Options of True, False and Both control the reference set display of Ejector Pin components. These options will be discussed in detail in the next section on Creating Pockets.

7-28




Standard Parts

Trim Surfaces Ejector Pins must be trimmed to the final parting face of the core body. Given that the final parting face of the core body may not always be the initial parting face defined by the Parting Surface, a second option called Mold Surface is provided.

Parting Surface The Parting Surface option should be used when the parting sheet sets found in the parting component" À are suitable to trim the target pin Á. This is the same sheet that was copied to trim the core body.

Á

À

Mold Surface The Mold Surface option should be used when the parting sheets that formed the core À are not suitable to trim the ejector pin Á. In this method, a region is extracted from the core body into the parting part and this region will be used to trim the ejector pin. Example: a solid patch Â was used to add material to the initial parting face of the core body. Use Mold Surface.

Â Á

À



7-29


Standard Parts

Fit Distance Fit distance or land refers to the length of tight diametric tolerance that is to be held at the tip of the ejector pin where it erupts from the core face. This tight tolerance is used to create a seal to prevent excessive flashing, yet allow enough room for venting and free movement with minimum mold wear.


7-30




Standard Parts

Pocket Creation After you add and position all standard parts, gating, and cooling lines, the last step to complete your mold assembly is Create Pockets.


MoldWizard will create pockets for any standard part that has been created using the following convention. The standard part must contain a FALSE" reference set comprised of a tool body to subtract from various mold plates to create the necessary pocket. The part must also contain a TRUE" reference set comprised of the solid bodies for the standard part. Internally, the FALSE body of the standard parts is linked to the target body parts, and is subtracted from the target body. We strongly recommend that you use Create Pockets function at the last stage of mold design. There are two reason for this:

First, after cutting the pockets, update performance will slow down due to the presence of WAVE linked bodies for each pocket.

Second, mold base updates could fail if standard parts fall outside a previously selected pocket target body.



7-31

Standard Parts

There are five methods provided to create pockets. The mold_defaults file controls which method will be your default, by MW_PocketMethod.

Target + Standard Special procedure for Target + Standard:


When the dialog first opens you select a target body or bodies.

Choose the OK or Apply button

A Selection dialog appears.

Proceed to select standard parts for which pockets are required.

Choose OK in the selection dialog to end part selection and create pockets in the target bodies.

Target Body This option allows you to select mold base plates or any part that is not a standard part," such as the core and cavity work piece inserts. When you choose OK or Apply MoldWizard will find all intersecting standard parts and cut pockets automatically.

Standard Part This option will allow you to select standard parts only. After you select the standard parts, choose the OK or Apply. MoldWizard will find all mold base plates intersecting with them and will cut pockets automatically. Only plates which are not blanked and are on the visible layer will be cut.

TIP Blank the fixed half of the mold base assembly before you use

Standard Part cut pockets for ejector pins. Only movable half plates will be found and cut with pockets. In general, the system will use only bodies which are selectable as targets for pocket cutting.

7-32




Standard Parts

Activity 7-2: Post Processing and Pockets

In this activity you will add more pins, and create pockets for standard parts. NOTE



Step 1 Open your mdp_tray_top tooling assembly. If needed, a staged assembly for this activity is in: ... / moldwizd / tray_3 / The tray feet" are long, thin sections with very little draft. Adjacent ribs have no draft. If the design must be used as modeled, it might be prudent for each boss to have an individual ejector pin. Notice that all feet are the same length. This fortunate consequence of intelligent design enables us to instance a single component pin.



7-33

Standard Parts

Step 2 Add a new size ejector pin one tray boss.

Choose Standard Parts, Hasco . . . À, Ejector Pins . . Á

À Á


Â Ã

Choose Z41 (Ejector Pin, Cylindrical) . . . Â

that the Position method is POINT . . . Ã

Change pin_d to 2 . . Ä

Ä

7-34

Choose OK.




Standard Parts


Choose Arc/Ellipse/Sphere Center.

Select the circular edge of any one foot.

When the pin has appeared, choose Cancel.

Step 3 Post Process the new ejector pin.


Choose the Ejector Pin icon.

The Eject Pin Post Processing dialog displays.

the default options shown.

Select the new ejector pin just added.

Choose OK in the Eject Pin Postprocessing dialog.



7-35

Standard Parts

Step 4 Create three new instances of the trimmed pin.

Choose the Standard Parts icon.

Select the new 2mm diameter ejector pin.


À

Á

Choose Position POINT . . À

Choose Add . . . Á

Choose OK in the Standard Parts dialog.


7-36


Continue to select each foot, until all four feet have one adjacent ejector pin.




Standard Parts

Step 5 Create Pockets in mold plates for the Ejector Pins and sprue bushing.

Choose the Create Pockets icon:



À

NOTE

Choose the Standard Part option . . À

The next instruction assumes that two of the sixteen pins already have pockets from an earlier activity.

Select the six 4.5mm pins that do not have pockets, all eight 2mm pins, and the sprue bushing.

Choose Apply.



7-37

Standard Parts

Step 6 Create Core Body Pockets for the Ejector Pins.

Choose Target + Standard . . . Á

Á


NOTE

Select a core insert. Hint: The status reads Solid Body: UM_CORE_BLOCK."

Choose OK.

The next instruction assumes that one of the eight pins already have pockets from an earlier activity.

Select all 7 pins without pockets that intersect the insert.

Step 7 Create a sprue bushing pocket in the cavity insert.

7-38

Choose Create Pockets Target + Standard.

Select either cavity insert, UM_CAVITY_BLOCK.

Choose OK.

Select the Sprue Bushing.




Standard Parts

Choose OK to end selection.

MoldWizard creates a pocket in the cavity workpiece for the sprue bushing.


Examine the mold assembly.


TIP You can use Blanking to pockets.

Select only the component you are interested in, and then choose All But Selected, OK.

Replace View with Tfr-Tri.

If necessary, Unblank everything. Hint: Ctrl-Shift-U

Step 8 Choose File Close Save All and Close. You will use this assembly again. This concludes Activity 7-2.



7-39

Standard Parts

Sliders and Lifters MoldWizard's Slider / Lifter function uses Standard Part Management to provide an easy way to design the sliders and lifters you need.


7-40




Standard Parts

Slides and lifters have two main parts: head and body. The head is dependent on the product shape. The body is composed of customizable standard parts.

Ç À

Ã

Â


Á

Å

Å

Â Ä

Æ

Push-Pull Slider À

Cam Drive Unit

Á

Attach Tool Section (Head) here

Â

Retainers

Ã

Slide

Ä

Baseplate

Å

Drive faces of Cam unit

Æ

Direction of Slider motion

Ç

Direction of mold plate motion



7-41

Standard Parts

Head Design There are two ways to create slider or lifter heads: Solid Head and Trim Body.

Solid Head The solid head method is often used in slider head design. To use the solid method to create a slider or lifter head, the Solid Split discussed on page 3-39 is ideal.


Create the head body in the core or cavity.

Add the appropriate slider or lifter.

WAVE link the head body into the slider or lifter body part.

Unite the head with the body.

Alteratively, you can create a new component and link the head to the new component. This alternative is preferable if the piece will be machined separately and assembled with fasteners.

Trim Body To use the trim body method:

7-42

Add a slider or lifter to the mold base.

Use Mold Trim trim a selected body with the core or cavity trim sheet.




Standard Parts

Slider and Lifter Sub Assembly Structure Slides and Lifter mechanisms will be added as sub assemblies. Each sub assembly contains the head, gibs, slides, dowels, or guides necessary to provide the desired motion. Lifter Sub Assembly (Component of Product Sub Assembly)


MoldWizard places the lifter sub assembly inside the product assembly. Slides and lifters pertain to a particular product; therefore, they are collected under the product part instead of under the misc sub assembly.



7-43

Standard Parts

Orientation of Slides and Lifters The YC axis of the WCS must be oriented along the direction of head motion, with YC+ pointing toward the undercut area of the cavity wall. The bitmap for each supplied assembly shows the YC+ direction À, origin Á, and parting line Â. Use this convention if you design custom slides or lifters.


Á

Â

Á

À

The slider or Lifter XC-YC origin will coincide with the WCS origin and the Y axis will be aligned with the YC+ axis. MoldWizard will match the parting position to the tooling regardless of the current ZC 0.0 location. Several standard parameters, including standard angles, may be chosen from selection lists on the Catalog tab.

7-44




Standard Parts

Activity 7-3: Sliders and Lifters

In this activity you will add Slides and Lifters to the two cavity family mold in the mouse project. NOTE



Step 1 Open your mouse project.

Open mouse / mouse_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / mouse_4 / Step 2 Add lifter(s).

Set the Display Mode to Partially Shaded.

Set or layer 1 as the Work Layer.

Choose the Slider Lifter icon:

.

The Slider / Lifter Design dialog opens. NOTE

In the following steps, please be very careful not choose OK or Apply until instructed to do so. Several steps of preparation are necessary before you Apply.



7-45

Standard Parts

Choose Dowel Lifter from the list . . . À

Á


À

Choose the Dimension tab . . . Á

Scroll if necessary, and choose riser_top . . . Â

Â Ã

7-46

Edit the riser_top value to 13 . . . Ã Hint: Do not forget to press Enter.




Standard Parts

Zoom in on the snap area of the lower mouse case.




7-47

Standard Parts

Locate the WCS at the center control point of the linear edge of the snap seat, as shown below:

Rotate the WCS 180 degrees about the Z Axis, into orientation shown above.

ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ How Does it Work? Z location of the WCS is irrelevant. The lifter will be placed at the origin of the WCS with respect to X and Y coordinates. The base Z position will be located correctly to the mold plate.

Choose OK in the Slider / Lifter Design dialog.

The Dowel Lifter is added to the mold assembly.

7-48

Fit the Display.




Standard Parts

A right view of the lifter top (shown) reveals that if the lifter were trimmed at the current location, the head would have a small area of with cavity steel . . À We can avoid that by repositioning the lifter 2.0 mm along the YC axis . . . Á A 2.0mm adjustment was determined using Analysis Õ Distance.

ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ À 2.0 mm

Á Step 3 Reposition the lifter.

Orient the view to Right, and zoom in as shown above.

Choose the Slider Lifter icon.

Select the lifter on the graphics screen.

Choose the Operation tab.

Choose Reposition.

Enter a Y value of 2.0, then press Enter.

The lifter moves to the position shown by dashed lines in the illustration.

Choose OK.



7-49

Standard Parts

Step 4 Trim the lifter head to match the core contour.

Choose the Mold Trim icon:

The Mold Trim dialog opens:


Select the yellow body of the lifter from the graphics window.

Choose OK in the Mold Trim dialog.

The lifter is trimmed in the product model. A trim direction confirmation dialog appears:

7-50

If the trim direction is good, choose OK.





Standard Parts

Step 5 Optional: If time permits, create another lifter on the opposite side of the part. TIP When locating the WCS for the second lifter, the default absolute orientation will be correct. Do not rotate the WCS when adding the second lifter.


When the second lifter is finished, choose File Save All.

Step 6 Activate the Upper Case product.

Select the Family Mold icon.

Double-click on mdp_mcu.

Make Layer 1 the Work Layer, and 10 Selectable.

If necessary, set the Display Mode to Partially Shaded.

The small block(s) created in the snap area of the upper case is now shaded in the display.



7-51

Standard Parts

Step 7 Create a slider. NOTE

In the following steps, please be very careful not choose OK or Apply until instructed to do so. Several steps of preparation are necessary before you Apply.


Choose the Slider Lifter icon.

Choose Push-Pull Slide in the list box.

Choose the Dimension tab.

The default slider width, 50mm, is significantly larger than the 6mm undercut width of the snap.

7-52

Edit the parameter wide to 25. Hint: Do not forget to press Enter.




Standard Parts

The origin of the slider needs to be positioned at the edge of the workpiece, in line with the small block that will form the undercut portion. Before adding the slider, the WCS needs to be moved to this precise position.


Zoom in on the snap area and locate the WCS on the small block as shown below.

The WCS origin is now correct in the XC-ZC plane, but needs to be moved back along the YC axis to the edge of the workpiece.



7-53


Standard Parts

Determine the YC distance from the WCS Origin to the Edge of the Workpiece using Analysis Distance.

ZC


YC XC

The YC distance should be roughly 26.2026... millimeters.

Move the WCS Origin -26.2026... in the YC direction so it aligns with the edge of the workpiece. Hint: Use copy/paste to copy the exact distance from YC Information into the Point Subfunction dialog Y window.

TIP If you happen to leave the Information window open, a listing of slider parameters will appear in that window when you choose OK. Parameters of a great many MoldWizard operations are displayed in the same way.

Cancel the Point Subfunction dialog. The Slider Lifter Design dialog reappears.

Choose OK.

The slider is added.

7-54




Standard Parts

Step 8 Wavelink the body of the slider to the small block that forms the undercut.

Window to mouse_mdp_mcu_prod.

Make layer 10 Selectable to see the small block that forms the undercut.

Use the Assembly Navigator to set the Work Part to mouse_mdp_mcu_core.

Dismiss the Assembly Navigator window.

Choose Application Assemblies.

Choose Assemblies Wave Geometry Linker...


The WAVE Geometry Linker dialog opens.

Choose the Body filter . . À

À



7-55

Standard Parts

Select the slider body . . Á

Á


Choose OK in the WAVE Geometry Linker dialog.

Step 9 Create a Solid Body that will form the Head of the Slider. The finished design will include a Slider Head that will be fastened to the face of the slider. This Slider Head will be created by extruding a solid body from the nearby face of the just linked slider body, and uniting this new body with the small solid that forms the undercut.

7-56

Use the Assembly Navigator to set the Displayed Part to mouse_mdp_mcu_core.





Choose Insert Form Feature Extrude...




Standard Parts

The Extruded Body dialog opens.

À


Choose Solid Face . . À

Select the front face of the slider . . Á

OK your selection.

Á

The initial Extruded Body dialog again displays.

Choose OK again.



7-57

Standard Parts

The Extruded Body Method dialog displays.

Â


Choose Trim To Face/Plane . . . . Â

The Vector Constructor dialog opens. A vector arrow displays, pointing away from the slider, toward the small block that will form the undercut.

Choose OK in the Vector Constructor dialog to accept the vector direction.

The Trimming Face dialog opens.

Ã

7-58

Choose Extend Trim Face . . . Ã




Standard Parts

Select the opposing face of the small block . . Ä

Ä


Choose OK . . Å

Å



7-59

Standard Parts

The Extruded Body Parameters dialog opens.


Æ

Choose OK again to accept the default zero offsets . . Æ

The Boolean Operation dialog displays.

Ç

7-60

Choose Unite . . . Ç

Cancel the Extruded Body dialog.





Standard Parts

È

The face of the slider provided a convenient profile for extruding this initial Slider Head design . . . . È The Slider Head is currently much bigger than necessary. The upper part extends into the cavity. The lower part need not extend into the guide slots. In the interest of time we will omit fastener design. Step 10 Offset the bottom of the Slider Head -19mm.

Choose Insert Feature Operation Offset Face...

The Offset Face dialog opens.

À Á

Set the Offset Value to -19 . . . À

Choose OK . . Á

The Offset Face Method dialog opens.



7-61


Standard Parts

Â


Choose Offset Faces . . . Â

The Offset Face Select dialog opens.

In the graphics screen, select the bottom face of the slider head . . . Ã

Ã

7-62

Choose OK.




Standard Parts

The bottom of the Slider Head is offset upwards 19mm.


Cancel the Offset Face dialog.

Choose Edit Object Display...

Select the Slider Head.

Set Partially Shaded to Yes . . . Ä

Ä

Å

Choose OK . . Å




7-63

Standard Parts

Now that the Slider Head has been created, material needs to be subtracted from the Core Block to generate the space it will occupy.

Step 11 Subtract the Slider Head volume from the Core Block.



The Tools dialog opens.

À

Choose Subtract . . . À

The Select a Solid dialog opens.

7-64




Standard Parts

In the graphics screen, select the Core Block as the target solid to subtract . . Á

The core block highlights.


Â Á

In the graphics screen, select the Slider Head as the tool solid to subtract . . . Â

Material for the Slider Head is removed from the Core Body.




7-65

Standard Parts

Step 12 Examine the Slider, Slider Head and Core Body interface.


Notice how the material on the slider head extends above the core parting surface into the cavity . . . Ã

Ã


7-66




Standard Parts

Step 13 Trim the slider head to the parting surface.

Choose the Mold Trim icon.

The work part changes to mouse_mdp_mcu_prod.

ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ À

In the graphics screen, select the Slider Head.

Choose OK . . À

If the trim direction is good, choose OK.



7-67

Standard Parts

When finished, the Slider, Slider Head and Core Body in the product part should appear as shown below:


Window to mouse_mdp_mcu_core.

Choose Format Move to Layer...

Move the wave linked slider and the untrimmed parent Slider Head body to Layer 255.

Window to mouse_top.


Step 14 OPTIONAL: If time permits, add a Slider and Slider Head to the opposite side of the part. NOTE

The WCS must be positioned to the small block and rotated 180 degrees about the +ZC Axis before adding the opposite side slider.

7-68

If you performed the optional step, choose File Save All.




Standard Parts

Step 15 Create pockets for the lifter(s) and slider(s) in the moldbase.

Set mouse_top as both the displayed and work part.

Choose the Create Pockets icon:



À

Choose Standard Part . . À

In the graphics screen, select any component of the slider(s) and any component of the lifter(s)

MoldWizard will highlight an entire lifter or slider sub assembly once you select and confirm any component of it.

Choose OK to create pockets in all of the mold base plates that intersect the slider(s) and lifter(s).



7-69

Standard Parts

NOTE


You already created a pocket(s) for the Slider Head(s) in the upper case core body using Tools Õ Subtract.

Step 16 Create a pocket(s) in the lower case core body for the lifter(s).


Choose the Create Pockets icon.

If necessary, choose Target + Standard . . . À

À

The cue line reads Select Target Bodies, then Standard Parts."

In the graphics screen, select and confirm the UM_CORE BLOCK as the target body. Hint: The lower half of the mold insert nearest the lifter.

Choose OK.

The class selection dialog appears. The cue reads Select Standard Parts."

7-70

Select and confirm any part of the lifter, or both lifters if two are present.




Standard Parts

Choose OK.


ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ mouse_mdp_mcu_core with slider pockets

mouse_mdp_mcl_core with lifter pockets



7-71

Standard Parts


mouse_top with sliders and lifters

Choose File → Close Save All and Close. This concludes Activity 7-3.

7-72




Standard Parts

SUMMARY

This lesson introduced the Standard Part Management dialog window and discussed the process of Adding Standard Parts to the mold base assembly. The process of Pocket Creation and the editing of a Standard Part Bill of Material was also covered in this lesson.


In this lesson you:

Selected standard parts from a standard parts catalog.

Added standard parts to a mold base assembly.

Edited standard part parameters and defined part locating points.

Created pockets to accommodate the added standard parts.

Added slides and lifters to a family mold assembly.



7-73

Standard Parts

ÏÏÏ 7 ÏÏÏ ÏÏÏ ÏÏÏ (This Page Intentionally Left Blank)

7-74




Sub Inserts

Sub Inserts Lesson 8

PURPOSE

OBJECTIVES

Many molds have high wear areas or sections that can be machined conveniently if a separate block or cylinder of steel is introduced. MoldWizard provides the Sub-Insert function to rapidly design and place auxiliary pieces in the tooling assembly.



Define and position Sub-Inserts as required.

This lesson contains the following activities. Activity

Page

8-1 Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9



8-1

Sub Inserts

Sub-Inserts Sub-inserts are used in areas on the core or cavity where:

intensive wear and tear occurs

machining is easier to perform on a separate body

A complete Sub-Insert is made up of:

a head, the contoured section that forms part of the product

a foot, the section that is attached or bolted into the assembly

Methods of Working MoldWizard provides two methods of creating sub-inserts:


8-2

Standard Part, the more recent and preferred construction method

Envelope, a legacy construction method




Sub Inserts

Standard Parts as Sub Inserts


The benefits of using standard parts as sub-inserts are:

sub-components may be attached

pocket-cutting bodies may be included with detailed features

The position of the sub-inserts is relative to the Product Model

The cavity or core shape is applied via the familiar mold-trim function



8-3

Sub Inserts

Envelope Method NOTE

The core and cavity must be created before a sub-insert component.

Envelope When you choose Envelope the dialog shown at the right appears. Working Part Create a sub-insert in either the core or the cavity. Parent geometry for the sub-insert component is defined in the part selected.


Working Part selection is available in all three dialogs of the Envelope method. Create/Edit Radio buttons govern whether you will be prompted to select geometry for a new Envelope or edit an existing one. Definition Method Extremity Faces - the same method as used for Create Box in the Tools dialog. Dimensions - you specify box or cylinder dimensions, then position the body relative to the WCS by typing numeric input or using dynamic sliders. Shape The Envelope can be a box or a cylinder. You may also create the sub-insert by profile split, a Tools button you practiced using in an earlier activity.

8-4




Sub Inserts

Head Forming Method There are four forming methods:

Trim by Parting Surface

Trim by Sheet

Trim by Solid Face

Intersection

Selection Steps There are two steps: Select Envelope - choose an Envelope to trim.


Select Tool Objects - select trimming objects or an intersection tool body. Extrude Edges to Sheet A tool kit allows you to remove unwanted sections of the head by extruding edges and trimming. You are prompted to select a start edge. The system displays a cone head vector indicating the direction it will search for the next edge, and the following dialog:

If you want only one edge, choose Selection Complete. If you want to traverse more edges, choose either Accept the direction, or Flip the direction, which ever is appropriate.



8-5

Sub Inserts

When you select a second and subsequent edges, the following dialog is active:

The dialog is similar in function to Traverse Loop. If you choose Selection complete only edges that were previously accepted will be used. The currently highlighted edge is not used. When you finish defining a series of edges, you will be presented with the Vector Constructor to define an extrusion direction, and the dialog below to define a distance:


The sheet constructed may then be selected in Method Trim by sheet by choosing the selection step Select Tool Objects.

8-6




Sub Inserts

Foot The Foot dialog creates a foot or body, the part of the insert that is fastened to a mold plate or main insert block. This step is critical to the management of sub-insert components. It is in this final step that a sub-insert component and linked geometry are created. You can create an arbitrary insert using MoldWizard Tools, such as Profile Split or Solid Split, then use only the foot step of Sub-Insert Design to complete the design and create a separate component part.


Sub-insert Part Name The default name is based on the project, product, and the current work part. You may over ride the default by entering a different name in the Sub-insert Part Name window. Create/Edit Select geometry for a new Foot or edit an existing one. Selection Steps Attach Face (on Head) - The system will prompt you to select an attachment face. Mounting Face (on Cavity) - the system prompts you to select a planar face on the work piece.



8-7

Sub Inserts

Parameter Entry A set of dimensions for the foot, based on the head size, are displayed in the expression list. A selected entry from the list may be edited in the text window below the list. Foot List A list of existing sub-insert Foot components allows you to easily select one for editing. Copy Sub-insert Component The Copy Sub-insert Component button creates a new instance of any previously defined head / foot component. You will be prompted to specify a position for the new instance.


Delete Delete allows you to Delete a selected sub-insert component. Edit File, Edit Database The File is a spreadsheet to control a selection list, in the case the Foot list. The Database is a spreadsheet which controls the parameters of foot parts which appear in the list.

8-8




Sub Inserts

Activity 8-1: Sub-Inserts In this activity you will create sub inserts for the small cylinders that form screw holes in your outlet box project using variations of the legacy envelope method.

ÏÏÏ ÏÏÏ 8 ÏÏÏ ÏÏÏ NOTE


NOTE

Illustrations vary slightly from your assembly because of the model and parting changes you made.

Step 1 Open your mdp_outlet project.

Filter to and open outlet/mdp_outlet_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / outlet_4 / Step 2 Define an envelope for a sub-insert at only one screw location.

Choose the Sub-Insert icon:



8-9

Sub Inserts

The Sub-Insert Design dialog appears.

À

Choose Insert Envelop . . . À The dialog updates to reflect the Envelope mode of working.


Á

Choose Envelope . . Á

The active product sub assembly becomes the displayed part. The work part is the core by default, or the cavity if you have been working in that part. The work layer changes to MW_InsertHeadLayer: 165 by default. The layer for core or cavity geometry is displayed. We want to create inserts in the cavity.

8-10




Sub Inserts

On the Sub-Insert Design dialog, set Working Part to mdp_outlet_cavity . . . Â

Â


The cavity layer becomes Selectable, and the core layer becomes Invisible. The cavity work piece should be visible. You will choose one cylinder for a screw hole and create a cylindrical envelope.



8-11

Sub Inserts

Orient the view so the cylindrical face of one of the screw core posts is visible and easy to select.

Make sure this face is easy to select.


Step 3 Create a cylindrical envelope.

In the Envelope dialog: Set Definition Method to Extremity Faces Set Shape to Cylinder.

À Á

The prompt reads Select extremity faces"

8-12




Sub Inserts

Select and confirm a cylindrical face as shown below:

Â


Choose Apply.

The following dialog appears:

Ã

Choose Circumscribed: you need a cylinder that surrounds the face you selected. Inscribed creates a cylinder that is contained inside the volume of face(s) you select.

A cylindrical envelope is created and highlighted for editing.



8-13

Sub Inserts

The Envelope dialog enters Edit mode. Edit the following parameters:

Set

D = 3/8

Set

Z2 = 2.125

Select values here:

Edit Values Here: to use the Enter key to activate your entry.


Choose Apply.

The cylinder is long enough to extend beyond the planar back" face of the work piece, making it easy to see and select, even if shading is enabled.

Choose Cancel to return to the Sub-Insert Design dialog.

Step 4 Complete the insert head by trimming the envelope to the cavity parting sheet.

In the Sub-Insert Design dialog choose Head.

The prompt reads Select target body." The default action is Trim by Parting Surface.

8-14




Sub Inserts

Select and confirm the cylindrical envelope, as shown below:

Select this body

Choose Select Tool Object from the Selection Step area:


The parting sheet is pre-selected.

Choose Apply.



8-15

Sub Inserts

The part is trimmed. The following dialog appears:

If the subinsert trim direct is correct, choose OK.

The insert head is trimmed to the same face as the cavity insert.

Choose Cancel to return to the Sub-Insert Design dialog.

Step 5 Create a foot", or attachment body, for the insert.


From the Sub-Insert Design dialog choose Foot.

Selection Step Attach Face (on Head) is preselected, and the prompt reads Select Attach Faces."

8-16




Sub Inserts

Select and confirm the circular end face of the head on the end that was NOT trimmed, as shown below.

Choose Selection Step Mounting Face (on Cavity):

The prompt reads Select Mounting Face."

Choose the planar face opposite from the cavity contours, as shown below:

Select this planar face



8-17


Sub Inserts


Change the Shape to Cylinder.

Choose OK.

The parameter list changes from Box to Cylinder parameters.

Choose Apply.

The sub-insert is created in the product sub-assembly.

The dialog changes to Edit mode.

8-18




Sub Inserts

Edit the diameter, as shown:

If necessary, select the D expression in the list

Key in the value 1 in the edit window

Press Enter


Choose OK to update the foot.

Step 6 Examine the cavity component.

Cancel from Sub-Insert Design.

Use the Assembly Navigator or the Window pull down to make mdp_outlet_cavity the displayed part.



8-19

Sub Inserts


Only the trimmed head is found in the cavity part. The foot does not exist in this part in any layer. Step 7 Examine the sub-insert component.

Use the Window More Parts... pull down to make mdp_outlet_cavity_si_1 the displayed part.

Make category ALL Selectable.


8-20




Sub Inserts

In the sub-insert part, you will see the complete sub-insert as an orange body. There is also a dashed yellow body, visible primarily around the foot" where it is larger than the orange body. The yellow body is used in conjunction with the Create Pockets function. You had a brief preview of pockets earlier in the class. Pocket cutting is practiced in the lesson on standard parts. Step 8 Prepare to create a sub-insert by profile split.

Use the Window pull down to make mdp_outlet_cavity the displayed part.

Make the following layer settings: 8 . . . . . . . . Work 165 . . . . . . Selectable Others . . . Invisible

We make 8 the work layer because it is MW_PartingCavityLayer, the layer where MoldWizard places cavity geometry. We are going to create a custom" envelope using profile split on the cavity body. Step 9 Create a separate body at the other screw location.

From the MoldWizard toolbar choose the Tools icon.



8-21


Sub Inserts

Zoom your view on the area of the other" screw - the one that does not have a sub-insert:

Edge loop for split


Choose Profile Split.

Select the work piece body as the target solid.

Select the edge shown above as the first edge, and use the traverse loop function to accept the remaining segment of the loop.

Select OK, the Vector Constructor dialog opens.

Fit the view.

In the Vector Constructor, choose the +ZC Axis as the sweep direction, then OK. Note: +ZC must be selected, even if it is already selected by default.

In the Extrude Distance dialog accept the default by choosing OK.

It is true the sweep is longer than necessary, but it will not hurt anything to accept it. After a few seconds the volume of the insert within the extruded sheet is split into a separate solid. All parameters are retained. The system uses an extracted body and opposite trim operations to perform the split."

8-22




Sub Inserts

Step 10 Define a sub-insert, using the body created by Profile Split as the head.

Choose the Sub-Insert icon, and Inset Envelop.

In the Sub-Insert Design dialog, choose Foot.

The display part becomes the mdp_outlet_prod sub assembly. The cavity should remain the work part.

If mdp_outlet_cavity did not remain as the work part, use the Working Part pull down in the Sub-Insert Design dialog to change it now.

Selection Step Attach Face is pre-selected, and the prompt reads Select Attach Faces."

Á

Select the circular end face of the solid created by Profile Split, as shown below.

Choose Selection Step Mounting Face.

Select the outer" face of the split body, opposite to the part cavity, as shown below:

Select this face as the Mounting Face

À

Change the Shape to Cylinder.

Choose APPLY to create the foot.


Select this face as the Attach Face


8-23


Sub Inserts

Set the parameters as shown below:

Type: D ........... Z_L . . . . . . . . . D_clr . . . . . . . . X1 . . . . . . . . . . Y1 . . . . . . . . . .

1 0.5 0.04 0 0


8-24

Choose OK to update the foot.

Cancel from the Foot and Sub-Insert Design dialogs.

Use the Window pull down to make mdp_outlet_top the displayed part.




Sub Inserts

Make Layers 165 and 175 Selectable.






8-25


Sub Inserts

SUMMARY

Sub-inserts are needed frequently. MoldWizard provides a robust standard parts approach, which requires little or no explanation, and a complex legacy system which you practiced in this lesson. In this lesson you:

Created sub-inserts using variations of the envelope method.


8-26




Gates and Runners

Gates and Runners Lesson 9

PURPOSE

OBJECTIVES

In this lesson you will use MoldWizard utilities to complete Gating and Runner systems.


Place Gates in a mold project.

Attach a Runner system to your gates.



Page

9-1 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9-2 Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19



9-1

Gates and Runners

Gates and Runner Systems Overview Plastic molds have flow pathways that direct the plastic to the mold cavities. The design of these pathways vary depending on part shape, size, and number of parts to be molded. The most common type of pathway is called a "cold runner". Cold runner systems have three types of channels; Sprues, Runners and Gates. 1. The Sprue is the path from the outside of the mold to the parting surface. A standard Sprue Bushing usually forms this section. 2. The Runner is a channel that is cut into the parting surface of the cavity, core of both that begins at the end of the Sprue and provides a pathway to the fill location of the mold cavity. 3. The Gate is the final pathway from the runner to the cavity. Gates come in a variety of designs depending on the molding characteristics and cosmetic requirements of the molded product. MoldWizard provides tool to design sprues, runners and gates.

CAVITY

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÏÏÏ 9 ÏÏÏ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÏÏÏ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÎÎÎÎÎÎÎÎÎÎ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÎÎÎÎÎÎÎÎÎÎ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ PRODUCT

GATE

SPRUE

RUNNER

CORE

9-2




Gates and Runners

Gate A gate is the part of the feed system that connects a runner with the mold impression. MoldWizard provides several gate types in a predefined library. You may customize the existing library, or extend it with your own gate designs. Balance - Balanced patterns are used for multi cavity molds when the gates are to be created in the same position in each instance. When a balanced gate is modified, repositioned, or deleted, all corresponding gates will update accordingly. Position - Gates may be installed in the cavity, core or both depending on the gate type. For example, sub-gates or fan gates almost always belong to just the cavity or core, whereas a round gate may be centered on the parting plane and cut into both the cavity and core equally. This setting determines whether the orientation of the gate to be created will be on the core or cavity side of the mold.


If the gate is cut into both the cavity and core at the parting plane, either option may be used. Method - There are two operation modes: Add and Modify. When a gate is selected, modification mode will be set. The parameters related to the selected gate will be displayed in the editing window. If you change to the Add option, you will be able to add a new gate according to the type and other parameters defined in the dialog.



9-3

Gates and Runners

Bitmap - a schematic image of the selected gate type is used to show shape, parameters, and origin location of the gate. Expression List - The available expressions are listed in a central window. The selected parameter is made available for edit in the Expression Edit window. Name - the system provides a default name for gate components. You may enter a name of your own choosing. Reposition Gate provides Translation and a Rotation dialogs, similar in function to the tools in Cavity Layout.

Delete Gate removes single unbalanced gates or all of balanced gate sets. If there are no other gates of the same name, the corresponding part file is closed.


The Edit File and Edit Data Base functions work the same as Standard Part, Mold Base, and other libraries. Reference allows you to change the parent part for Balanced gate components. Gate components are added to the part designated by Reference. Solid bodies are WAVE linked into the FILL part. The default parent for gate components is the product or PROD subassembly. MW_GateReferenceDisplay in the default file controls if the Reference pull down appears in the dialog. If set to 1 the list appears. If set to 0 the list does not appear and components will always be added to PROD.

9-4




Gates and Runners

Gate Point Indication The gate point sub-function enables you to indicate the gate origin point. When you choose Gate Point Indication, the Gate Point dialog will appear:

Point Subfunction allows you to create a point using the familiar UG point interface. Face/Curve Intersection creates the intersection point between a face and a selected curve or edge. Plane/Curve Intersection creates the intersection point between a plane and a selected curve or edge. TIP Do not edit Gate Design Parameters until a Gate Point has been specified. The action of defining a Gate Point Location will cause all parameters to reset to their default values.



9-5


Gates and Runners

Point on Curve works the same way as points for variable radius and variable taper. You first select an edge or curve. A "work point" will be created on the end of curve.

You can move the highlighted point along the curve by following methods: drag the % scroll bar drag the value scroll bar numeric input % real value input Point on Face - A point is created on a face by this function. A work point will be created on the center of the face. The point is adjusted by sliders or numeric input, either in XYZ or along a specified vector direction.


Delete Gate Point - Deletes a selected Gate Point.

9-6




Gates and Runners

Activity 9-1: Gates

In this activity you will add gate components to the two cavity tray mold. NOTE


Step 1 Open the tray mold assembly.

Open mdp_tray_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / tray_4 /

Set the view to TFR-TRI.

Step 2 Define Initial Gate Parameters.

Choose the Gate icon.

ÏÏÏ 9 ÏÏÏ ÏÏÏ NOTE

Do not choose OK or Apply in the following steps until instructed to do so!



9-7

Gates and Runners

The Gate Design dialog opens.

À

Á

Â


Set Balance to Yes . . . . . À

Set Position to Cavity . . . Á

Set Type to submarine . . Â

Set Reference to mdp_tray_prod . . Ã

Ã

9-8




Gates and Runners

Step 3 Define the Gate Point Location.

Choose Gate Point Indication . . . À

À The Gate Point dialog opens.

Á

Choose Point on Face . . . . Á




9-9

Gates and Runners

The Face Selection dialog opens.

Â

Select the back, outer face of the product model . . . . Â

The Point Move on Face dialog opens.

Ã


Ä

Å Æ

9-10

Accept the default X value . . . . Ã

Y = 0.000 . . . Ä

Set Z = 8.000 and press Enter . . Å

Choose OK . . Æ




Gates and Runners

The Gate Point dialog reappears.

Ç

Choose Back to return to the Gate Design dialog Ç

Step 4 Define the remaining Gate Parameters and apply the Gate Design.

and set Gate Parameters as necessary: d ........... A ........... B ........... HD . . . . . . . . . . OFFSET . . . . .

1 15 40 12 1


Choose Apply.



9-11

Gates and Runners

The Point Constructor dialog opens. The prompt reads Pick a point - Specify inferred point."

Choose Existing Point in the Point Constructor dialog.

Select the existing point on the back outer face that was created in the previous step.

A vector arrow appears on the coordinate system at the base of the sprue. The Vector Constructor dialog opens. The correct gate orientation is in the direction of material flow into the mold. For this mold assembly, it is along XC+ or XC-.

Set the applicable XC vector icon in the Vector Constructor, and then choose OK.

The system creates gates for both cavities.


NOTE

9-12

If two gates do not appear as illustrated, consult with the instructor to determine the reason(s).




Gates and Runners

Cancel the Gate Design dialog.

Choose File Save All. Do not close the part file. This concludes Activity 9-1.




9-13

Gates and Runners

Runner The runners are filling paths from the sprue to the gates. Runners are designed by defining a path that the runner will follow and a cross section shape for the channel along the path. The size and shape of the section may change at various points along the runner channel. The MoldWizard Runner module provides tools for creation and editing of paths and cross sections of runners. The runner channels are created by sweeping the cross section along the guide strings. The channels are created in a single part file and will be subtracted from the core and cavity after the design is confirmed. MoldWizard has five predefined types of cross section: circular, trapezoidal, parabolic, hexagonal and semi-circular. By default, all the geometry is created in the FILL component. MoldWizard recognizes the default part for the placement of gating and runners by the presence of the part attribute UM_GR".


Runner Design Steps

9-14

Define guide string(s)

Projection onto parting faces

Create runner channels




Gates and Runners

Define Guide String There are three methods to define a guide string. The method you choose will depend on the complexity of the runner channel, parting surface and requirements for parametric adjustment. The first one is importing a sketch pattern, the second is creating curves in pre-defined shape, and the third is to select existing curves.

Sketch Pattern The import Sketch Pattern method uses six predefined parametric sketch patterns to define adjustable runner guide patterns. Sketch patterns may be selected from the Available Patterns pull down menu and imported to the runner component by pressing OK or Apply. defined runner patterns may be added to the option menu by creating a sketch model, a ing spreadsheet, bitmap image and adding their paths to the sketch pattern file. (This general procedure is used in several modules, and is explained in detail in the on line documentation).


Available sketch patterns include 2, 4, 8, and 16 cavity patterns, a circular pattern, and an s-shaped pattern.



9-15

Gates and Runners

Curves through Points The dialog offers four pre-defined shapes, each located by two points. Guide String Shape is a pull down list offering the four shapes shown at the right. Choosing Point Subfunction will initiate prompts to select the two points. When existing curves are selected and highlighted, Incremental Length, Reposition, and Delete are available to make edits.

ÏÏÏ 9 ÏÏÏ ÏÏÏ Add / Remove Curves from Strings When the Add / Remove Curves from Strings option is active, you may use MB1 select to add existing curves to a guide string, and Shift+MB1 deselect to remove curves from a guide string.

9-16




Gates and Runners

Projection onto parting faces If the parting surface is non-planar, the linear patterns provided would lie inside the core or cavity tool steel at various places. You will want to project runner patterns on to the parting so that channels lie on the parting.

Curves Select guide curves to project to the parting.


Parting Faces Select faces on which to project the curves. Copy Method Move creates projected curves. The originals are deleted. Copy leaves the original curves and creates projected curves that are not associated. Associate creates projected curves that are associative to the original curves and to the selected parting faces.



9-17

Gates and Runners

Create Runner Channel MoldWizard will automatically find all the guide strings in the work part and create a swept runner channel along each guide string using the chosen cross section, its parameters and other options. When you select an existing runner channel, the system will retrieve the selected channel data and present it for modification. There are five Cross Section shapes available; circular, parabolic, trapezoidal, hexagonal and semi-circular; as shown below:


Other Runner Design Options Reposition and Delete With these buttons you can move or delete a selected runner channel.

9-18




Gates and Runners

Activity 9-2: Runners

In this activity you will add a runner component, and create the runner and gate pockets in the two cavity tray mold. Step 1 Open the tray mold assembly in the top view.

If necessary, open mdp_tray_top.

If needed, a staged assembly for this activity is in: ... / moldwizd / tray_5 /

Orient the display to Top.

Step 2 Define the runner guide string.

Choose the Runner icon.




9-19

Gates and Runners

The Runner Design dialog opens. Define Guide String is the default selection step . . . . À Sketch Pattern is the default Definition Method . . . . Á

Á À Â

Ã


9-20

Set Available Patterns to 2 Cavities . . . Â

Set guide string length A to 32 . . Ã Hint: Do not forget to press Enter.

Choose Apply.




Gates and Runners

A guide string 32mm long appears . . . . . Ä between the two submarine gates . . . . . Å

Å Å

NOTE

Ä

This mold design has a planar parting surface; projection of the guide string onto the parting sheet is not required.

Step 3 Create the runner channel.

ÏÏÏ 9 ÏÏÏ ÏÏÏ À

Choose the selection step Create Runner Channel . . À



9-21

Gates and Runners

The lower portion of the Runner Design dialog changes.

Á Â

Ã Ä

Set or the following parameters: Cross Section . . . . . . . A .................. Runner Location . . . . . Cold Slug Position . . .


Circular . . . . . . 5.5 . . . . . . . . . . Core . . . . . . . . . Both End . . . . .

Á Â Ã Ä

TIP Circular runners are symmetric in the Core and Cavity. Either location is appropriate for circular runners.

9-22

Choose OK to create the Runner profile.

Cancel the Runner Design dialog after the part updates.




Gates and Runners

Å

The illustration shows the 5.5mm diameter runner extending along the core and cavity boundary between the two submarine gates . . . Å Step 4 Create the gate and runner pockets.

Choose Create Pockets.



Choose Target + Standard.

The cue line reads Select Target Bodies, then Standard Parts.



9-23

Gates and Runners

The core and cavity bodies are the target bodies that will receive pockets defined by the gates and the runner segment.

In the graphics window, select the core and cavity bodies. Hint: UM_CORE_BLOCK and UM_CAVITY_BLOCK.

Choose OK in the Create Pockets dialog.

The cue reads Select Standard Parts." The gate and runner components of the fill part define pocket geometry. NOTE

Selecting any one of the fill components will select them all.

In the graphics window, select either gate or the runner.

Choose OK on the Standard Parts dialog box.

MoldWizard creates the runner and gate pockets in the cavity and core.


9-24




Gates and Runners

Step 5 Examine the Core Body.

Choose Window More Parts and open mdp_tray_core.

Step 6 Examine the Cavity Body.

Choose Window More Parts and open mdp_tray_cavity.




9-25

Gates and Runners

Step 7 Restore the display to mdp_tray_top.

Select Window mdp_tray_top

Use the Assembly Navigator to make mdp_tray_top the Work Part.


Set the view to TFR-TRI, wireframe, hidden lines visible.

Choose File Save All. Do not close the part file. This concludes Activity 9-2.


9-26




Gates and Runners

SUMMARY

MoldWizard provides customizable libraries of gates and runners, and the Electrode utility, to complete your mold tooling design. In this lesson you:

Placed Gates for your tray.

Added a simple runner system to your tray project.

Created pockets for all fill components.




9-27

Gates and Runners



9-28




Cooling Channels

Cooling Channels Lesson 10

PURPOSE

OBJECTIVES

The current approach to cooling uses a Standard Parts approach to specify both drilled channels and a variety of plumbing components. A previously used approach was focused on schematic circuit design. You may encounter the older method if your company has legacy mold data.


Add Standard Cooling Parts to a tooling assembly.

Add Cooling Lines to a tooling assembly.

This lesson contains the following lessons. Activity

Page

10-1 Cooling Using Standard Parts . . . . . . . . . . . . . . . . . 10-5 10-2 Schematic Cooling Circuit Design . . . . . . . . . . . . . 10-26



10-1

Cooling Channels

Cooling When you choose the Cooling icon a Cooling Method dialog appears.

À

Á

Choose Channel Design À to activate the legacy cooling subsystem described later in this lesson. Choose Standard Part Á to activate the current (preferred) subsystem. Set the MW_CoolInterface value in the mold_defaults file to enable the desired system(s). MW_CoolInterface = 0, use guide line method. MW_CoolInterface = 1, use standard part method. MW_CoolInterface = 2, display dialog to select guide line or standard part method. By default, and in the classroom, MW_CoolInterface = 2.





Cooling Channels

Cooling Component Design When you choose Standard Part on the Cooling Method dialog, the following dialog will appear:



10-3

Cooling Channels

The cooling hole standard part s a variety of component types, such as pipe-plug, baffle, connector-plug and extension plug. Component configuration may be changed after the hole is installed. The Standard Parts cooling method has two main steps:

add a standard part that forms the hole

add a component to a selected hole

Hole Procedure

Choose a Parent: For holes in the mold base choose *_cool." For holes in inserts choose *_prod."

Choose the component type from the COMPONENT_TYPE option menu.

Choose a thread size.

Choose Apply.

Select a placement plane and proceed with PLANE object placement.

Edit the cooling hole position and dimensions using the Operation and Dimension pages.

Component Procedure

With the hole selected and highlighted, choose a component type from the listing window of the Cooling Component Design dialog.

Set the size.

Choose Apply.

The component will then be added as a child of the previously selected cooling hole component. To change the component type:


Remove the previously installed component.

Edit the COMPONENT_TYPE of the cooling hole.

Choose and install a replacement component.




Cooling Channels

Activity 10-1: Cooling Using Standard Parts In this activity you will use the Standard Part approach to Cooling Component Design. The design requires that some of the cooling channels be placed at an angle. Do not worry about the mechanical interface between the cavity insert and mold plates, or choosing the proper parent for components you will add. This design approach was simplified to help you to familiarize yourself with the Cooling Component Design dialog and the positioning options available for the Cooling Hole standard part.



10-5

Cooling Channels

NOTE


Step 1 Open assembly desk_org_top from ... / moldwizd / cooling.

Step 2 Initiate Cooling Component Design.

From the MoldWizard menu bar select the Cooling icon.

ChooseStandard Part . . . . À

À





Cooling Channels

Step 3 Create Cooling line # 1.

From the Cooling Component Design dialog, if necessary, choose the Catalog tab À, and the Cooling Hole option Á.

À Á

Set the slider for Hole_1_Depth to 4.000 . . . Â

Â



10-7

Cooling Channels

Choose the Dimension tab . . . Ã

Ã

Set the value for C_CBORE_DEPTH to 0.375 . . . Ä Hint: Do not forget to press Enter.

Ä

Choose OK.





Cooling Channels

From the graphics screen select and confirm the Front Face of the cavity insert as shown:

The view is oriented to the plane of the face you selected. The point constructor displays. The cue reads: Pick up a point to add standard part: - ..." The last part of the cue varies, depending upon how or if the Point Constructor was last used in your session.



10-9

Cooling Channels

In the Point Constructor dialog choose Cursor Location.

The cue now reads: Pick up a point to add standard part: - Indicate location of point with the cursor."

Indicate a point on the graphics screen at approximately the cursor location shown:

X

The specified hole part is added, and a Position dialog appears.





Cooling Channels

From the Position dialog, in the Reference Point area, choose Face Center . . . Å

Å

Temporary dimension lines appear on the screen.

Choose Drag . . . Æ

Æ Temporary coordinates display at the cursor location. These coordinates snap to rounded values determined by the settings X Increment, Y increment, and Drag Decimal Place.

Move your cursor to the position where: X = 2.8 Y = 1.6

Indicate that location by clicking.



10-11

Cooling Channels

TIP You may also manually edit the X and Y values on the Position dialog as Offset D1 and D2.

Choose Cancel to dismiss the Position dialog.

The Cooling Method dialog appears. Step 4 Create Cooling line # 2.

Repeat the previous procedure, using the following parameters: HOLE_1_DEPTH . . . . 6.000 C_BORE_DEPTH . . . . 0.0 ANGLE_X . . . . . . . . . . -45 Hint: You may achieve greater angle variation than the slider can achieve by editing Angle_X on the Dimension tab. Face as illustrated.





Cooling Channels

Indicate in the approximate position shown:

X

Choose the Face Center.

Edit into position: D1 = 1.2 Hint: Press Enter after each change. D2 = 1.6

Step 5 Create Cooling Line # 3.

Repeat the preceding procedure, using the following parameters: HOLE_1_DEPTH . . . . 6.000 C_BORE_DEPTH . . . . 0.0 ANGLE_X . . . . . . . . . . 45 NOTE

We use Plus 45° on this side!




Cooling Channels

Select the face illustrated:

From Face Center: D1 . . . . . . . 1.2 D2 . . . . . . . 1.6


Result of Step 5.

10-14




Cooling Channels

Step 6 Create Cooling Line # 4. Cooling Line # 4 is similar to cooling line # 1, except that it does not have a counter bore. HOLE_1_DEPTH . . . . 4.000 C_BORE_DEPTH . . . . 0.0 ANGLE_X . . . . . . . . . . 0.0

Indicate a point the same distance from the face center as the first hole, except the opposite side:

From Face Center: X . . . -2.8

or

D1 . . 2.8

Y . . . -1.6

or

D2 . . 1.6


Result of Step 6.



10-15

Cooling Channels

Step 7 Create Cooling Line # 5. HOLE_1_DEPTH . . . . 6.250 C_BORE_DEPTH . . . . 0.0 ANGLE_X . . . . . . . . . . 0.0 From Face Center: D1 . . 2.2 D2 . . 1.6

Step 8 Create the final cooling line # 6. HOLE_1_DEPTH . . . . 1.500 C_BORE_DEPTH . . . . 0.375 ANGLE_X . . . . . . . . . . 0.0 From Face Center: D1 . . 2.0 D2 . . 1.6


NOTE

10-16

The placement face and relative position for the final hole is illustrated on the following page.




Cooling Channels

3

2

4 5

6

1

Your cooling lines should look similar to the figure shown above. that you can always select a given cooling line and modify its dimensions and position. If you have difficulty, ask your instructor for assistance. Step 9 Add Connector Plugs to cooling lines 1 and 6.

If necessary, once again choose Cooling Standard Part.

Select cooling line #1.

From the Cooling Component Design dialog choose the Catalog Tab.

Choose CONNECTOR PLUG and then choose Apply.

Choose O-RING and then choose Apply.

Select Cooling Line # 6 from the graphics window and repeat the above steps.




Cooling Channels

Step 10 Add Pipe Plugs to the remaining cooling lines.

If necessary, choose Cooling Standard Part.

From the graphics window select Cooling Line #2.

Choose PIPE PLUG from the Catalog Tab and Apply.

Select Cooling Line # 3.

Choose PIPE PLUG and then Apply.

Repeat for Cooling Line #'s 4 & 5.

Step 11 Create pockets for the cooling lines and components.

From the MoldWizard main menu bar select the Create Pockets icon.

Using the Target + Standard option select the cavity insert from the graphics window then choose OK. Now choose Select All then choose OK.

Step 12 Preview the BOM function.

Choose the Bill of Material icon.

Choose Standard Parts Only and BOM Record Edit.

The cooling components you added are shown in a large window on the BOM Record Edit dialog. You will learn about Bill of Material functions in an lesson. Step 13 Save your work.


Choose File Close Save All and Close. This concludes Activity 10-1.

10-18




Cooling Channels

Cooling Channel Design Cooling Channel Design is a legacy tool that allows you to interactively create cooling channels in a mold assembly. If you use Define Guide Path tools to construct guide curves, there is associativity between channels and their inlet face, and parametric positioning of each complete circuit. You can also create channels from curves created in Unigraphics.

Channel Design Steps There are two design steps in the dialog:

Define Guide Path

Generate Cooling Channel

Balanced and Non-Balanced The radio buttons allow you to choose between a balanced design and an non-balanced design. The difference is in the work part in which the channels are created. A balanced design is created in the PROD part, and appears in all inserts. A non-balanced design is created in the COOL part. Channels in the COOL part are common to the entire tooling assembly.



10-19

Cooling Channels

The Assembly Navigator illustration below shows the Work Parts for both Balanced and Non-Balanced cooling channel creation.

Work Part is COOL for Non–Balanced construction.

Work Part is PROD for Balanced construction.

TIP Before creating cooling channels, define your layout and add the mold base. Create the channels in a completed layout.

Define Guide Path There are two methods to create a cooling guide path:

Use the sketching tool provided by the module.

Create the guide path using standard Unigraphics modeling, and import it into the cooling module.

If you create curves in native Unigraphics you must choose your work part according to the Cooling type you intend to use, Balanced or Non-Balanced. The Balanced method uses the PROD part as the work part; therefore, for a Balanced system create curves in the PROD part. Likewise, for a Non-Balanced system, create curves in the COOL part.





Cooling Channels

Create The Create button activates Sketching" with the Cooling Module. This is a tool which permits you to construct a series of associated smart" lines which, together, make up a complete cooling path. Lines are associative to the face on which they are placed. The first line is the master for positioning; it may be positioned. Each successive line is a child" of the one before it. If a parent is moved, all children move with it.

Create Procedure

Select an inlet face, from which the first channel is drilled.

Adjust the length if desired

Select a second face, from which the second channel is drilled.

A second guide path will automatically be created at an angle normal to the second face to up with the first guide curve.

Adjust the position of the second guide line by the slider or the input window - the line will glide along the first line.

Continue to add curves in the same manner as the second curve until the circuit is complete.

At any time after the first line is defined, choose Create/Edit Guide Path Position to create positioning constraints. The first line, at the inlet face, is the point constrained.

Click OK to complete the operation.



10-21

Cooling Channels

Length All cooling guide lines start with a default length. The first cooling line has a default length equal to the full width of the mold plate or workpiece body selected. Subsequent lengths depend on the distance between the selected face and the previous cooling line. The length slider is used to adjust a line length. NOTE

The system constrains the length of child curves to be at least the distance from the selected face to the parent guide curve, to assure that a connection is maintained.

Position A slider control and a text input box are provided to adjust the position of any child guide line along its parent. NOTE

The Position input box and the position slider are grayed out as the first line is created. Its position is controlled by constraints, using Create/Edit Guide Path Position.





Cooling Channels

Delete Guide Path Delete a complete guide path by selecting any member line. Delete Guide Line Delete a selected guide curve. Any child curves will also be deleted. Create/Edit Guide Path Position Create/Edit Guide Path Position initializes positioning for the first line of the path. Since there is associativity from the first line to each child, the entire guide path is moved as the first line is positioned. Subsequent lines can be repositioned, each relative its immediate parent, using the position slider or text input box.

Add/Remove UG's Curve This button allows you to import" guide curves created by normal UG methods. NOTE

The curves must be created in the appropriate work part.

Move cursor over to the graphic area and select the native UG curve.

Show Cooling Channel Relationship Numbers appear on the screen to indicate parent child relationships in the current guide path.



10-23


Cooling Channels

Generate Cooling Channels Diameter Enter the desired channel diameter in the text input window, or choose from common pipe sizes.

Hole Type Threaded Hole gives a channel diameter equal to the tap drill size for the selected diameter. Clearance Diameter for the pipe size specified is the second choice.

Start Type Use a pull down list to choose between:

Flat ended

Counterbored

End Type


Flat ended

Counterbored

Blind end

Blind with a specified extension past another channel.




Cooling Channels

Delete Cooling Channel

Deletes a selected channel body.



10-25

Cooling Channels

Activity 10-2: Schematic Cooling Circuit Design

In this activity you will create a cooling circuit pattern defined by a drawing on the following page.

NOTE


Step 1 Open mdp_cup1_top from ... / moldwizd / cup1_4 / To run channels through mold plates, we would need to import the mold base before proceeding. We will skip importing a mold base simply to make your screen easier to interpret. The circuit you will create is simplified to permit you to quickly experience the use of Cooling Circuit Design.





Cooling Channels

The layout of cooling lines is shown below. Guide lines are shown in bold. The line marked À is the Master line. Parent relationships are indicated by the symbols Á, Â and so on. The face with the counterbored openings should be on the exterior of the layout, to permit connections. There are several valid choices of placement faces for the layout. The faces illustrated were chosen to minimize the number of faces containing drill start points, only two. This optimizes the number of machining setups required. Reference edges and values of Z dimensions are provided later.

5.500

Ä 1.500

Ã À 5.500

Á 0.625 TYP. (4) LINES

Â



10-27

Cooling Channels

Step 2 Create a master line to begin a balanced cooling circuit in the inserts.

NOTE

Choose the Cooling icon.

Choose Channel Design.

One of the four part instances displayed becomes the work part. We expect it to be the one shown . . . À

Identify which faces correspond to an exterior" position on the layout relative to the WCS. You will select an exterior face, for example the face shown as Á, when you roughly place the Master line.

À

Á

The hierarchy of guide lines is straightforward in this part. When editing other parts, particularly if you were not the original designer, this feature is very useful to reveal the parent child relationship of guide lines.





Cooling Channels

Place your cursor over the face previously identified as an exterior face, in the relative position approximately half the cavity insert height, and one third of the total distance from left to right.

Select the face, indicating by a cursor location approximately half the insert height, and approximately one third the distance from the outside of the layout.

TIP If necessary, you can delete a guide line or an entire guide path. When you delete a line, all child lines will also be deleted. Use Show Channel Relationships to reveal the parent child relationship of lines.




Cooling Channels

Adjust the length to 0.625, then press Enter . . . . À

À


As you select faces, that (1) you want fittings only on exterior faces, and (2) you want to drill into only two faces.

10-30




Cooling Channels

If necessary, refer to the illustration on page 10-27 for positions and dimensions. Guide lines are created in MW_CoolingPathLayer, 181 by default. The cooling line À should remain highlighted. Size and position should appear approximately as shown below:

Á

À

NOTE

From this page onwards, other occurrences of the product are omitted for visual clarity.

Step 3 Create guide line two.

Select the next face Á, with relative orientation to the first as shown.

Adjust Length to the minimum value the system will allow.

The minimum length available depends on where you placed the cursor for the first line. You will adjust that position to exact values later.



10-31


Cooling Channels

Adjust the Position to 0.625

TIP to press Enter after editing values on the dialog.

Á

NOTE

The system might occasionally truncate a value, for example, 0.625 to 0.624999... Do not be concerned about such small discrepancies.

Step 4 Create guide line three.


Place the third line on the same face as the first.

Adjust the line to these values: Type: Length . . . . . . 4.875 Position . . . . . . 0.625

10-32




Cooling Channels

Step 5 Create guide lines four and five.

Place the fourth line on the same face as the second. Type: Length . . . . . . 4.875 Position . . . . . . 4.875

Ã

Â

Ä

Place the fifth guide line on the same face as one and three. Type: Length . . . . . . 4.875 Position . . . . . . 4.875



10-33

Cooling Channels

Step 6 Create a positioning constraint for the circuit.

Choose Create/Edit Guide Path Position.

The Create/Edit Guide Path Position dialog appears.

Create position constraints by selecting both lines as shown, and then enter values D1 and D2 in the dialog: D2 = 2.50

D1 = 1.50

D1, D2

Activate the toggle for Show Channel Relationship.

If necessary, edit the position of any guide lines that are out of place.

To Edit a cooling guide line:


Select the line you want to edit.

Use sliders or enter new values in the appropriate window.

Enter values whenever the exact dimensions are known.

10-34





Cooling Channels

Step 7 Generate the cooling line solid bodies.

Choose Generate Cooling Channel . . À

The Cooling dialog changes to Generate mode.

Change End Type to Blind End with Extension . . Á

Choose Apply . . Â

À

Á

Â

Cooling lines are generated, and remain highlighted for editing.



10-35


Cooling Channels

Step 8 Modify parameters of specific cooling lines.

Change the Display Mode to Partially Shaded.

Like standard parts, gating, and runners, cooling lines are partially shaded. Since all lines are highlighted, it is easy to change all of the extension values with one edit. Type: Extension . . . . . . . . . . . 0.18 (Enter)

Choose Apply.

Shift-deselect all lines except the first and last, lines one and five. If necessary refer to the illustration on page 10-27.

Edit the start type for lines one and five: Type: Start Type . . . . . . . . . . . Counter Bored End Counterbore Diameter . . . . . . . 0.6875 (default) Counterbore Depth . . . . . . . . . . . . . . . . . .06

The values used are intended only to demonstrate editing.

Choose Apply.

Cancel from the Cooling dialog.





Cooling Channels

The bodies created in MW_CoolingChannelLayer, 180 by default, may be subtracted using the pocket function.

Step 9 Create pockets for the cooling circuit.

From the Create Pockets dialog choose Target + Standard.



10-37

Cooling Channels

Select any instance of the work piece cavity insert.

OK and Apply are now available.

Choose OK.

When the Selection dialog appears, select any cooling channel.

Choose OK.

Pockets are created for the cooling channels. Step 10 Test pocket associativity by editing counterbore parameters on two channels.

Choose the Cooling icon.

Choose the Generate Cooling Channel icon.





Cooling Channels

Select the two channels with counterbores.

Á

NOTE

À

Parameter values in the dialog do NOT update to reflect your selections.



10-39

Cooling Channels

Edit in 5 places as shown below. to hit Enter to activate each change to a parameter window.

À Á Â Ã Ä





Cooling Channels

Choose Apply.

Both the cooling circuit and its associated pockets update.

Cooling circuit design after editing.

Cancel from the Cooling dialog.







10-41

Cooling Channels

SUMMARY In this lesson you:

Created cooling components using the Standard Parts approach.

Designed a cooling circuit using the legacy circuit design system.





Electrode Design


Electrode Design Lesson 11

PURPOSE

Unlike most other functions within MoldWizard, electrodes are not components of a finished mold tooling assembly. Electrode functionality is provided because electrode design is a common and very necessary stage of the mold manufacturing process.

OBJECTIVES


Design Electrodes using the Standard Part approach.

Design Electrodes using the legacy envelope, head, and foot approach.

This lesson contains the following lessons. Activity

Page

11-1 Electrodes Using Standard Parts . . . . . . . . . . . . . . 11-4 11-2 Electrodes Using Envelope . . . . . . . . . . . . . . . . . . . 11-17



11-1

Electrode Design


Electrode Design In mold design, some complex areas in the core, cavity or sub-insert are impractical to machine. Using an electrode type EDM is a solution to manufacturing such complex areas. There are two methods for electrode design. The more recent and default choice is based upon standard parts.

retrieve a library tool

trim the tool to the appropriate mold steel

The legacy system provides a rich set of tools to define:

11-2

envelope or bounding faces

head or active tooling part

a coordinate system to assist with EDM set up

foot or attachment mechanism

electrode definition drawing




Electrode Design

Standard Part Approach The benefit of using a standard part is that subcomponents may be attached and pocket-cutting bodies may be included with detailed features.



11-3



Electrode Design

Activity 11-1: Electrodes Using Standard Parts In this activity you will create a cavity electrode using a standard part and mold trim. NOTE


Step 1 Open the mdp_tray_top assembly file in ... / moldwizd / electrode /

When MoldWizard is active, open mdp_tray_top.

Step 2 Start applications Assemblies and Modeling. Step 3 Initiate the Electrode Design Process.

Choose the Electrode icon.

The Electrode Design dialog opens.

or set Insert Standard Part . . À

À Á

11-4

Choose Electrode Library . . . Á




Electrode Design


The Electrode Design standard part dialog displays.

Set or the options Â Ã Ä shown below:

Ã

Â

Ä

Step 4 Enter data on Electrode Design Catalog tab.

Set or these data fields: CLEAR_LEVEL . . . . . 5 . . . À CHAMFER . . . . . . . . . . 2 . . . Á CHAMFER_CORNER 3 . . . Â

À Á Â



11-5

Electrode Design


Step 5 Enter the data for electrode design Dimension Tab fields. Reference Information: Cavity Insert:

Y overall = 165.00 X overall = 110.00 Z overall = 56.00

Cavity:

Y overall = 118 X overall = 60.62 Z depth below P/L 31.90

Choose the Dimension tab . . . À

À

Set or these values: Hint: to press Enter after every edit! X_LENGTH . . . . . . . . . 65 Y_LENGTH . . . . . . . . . 120 BURN_LEVEL . . . . . . 35 FIXTURE_LEVEL . . . -25

Choose Apply.

The Point Constructor dialog displays.

11-6




Electrode Design


Step 6 Position the Electrode.

Choose Reset . . . . À

Set XC = .55 . . . . . . . . Á

Á

À

Choose OK.

A cavity electrode is configured and added to your assembly.

Cancel from the Point Constructor dialog.

Choose Back on the Electrode Design standard parts dialog.

The Electrode Design main dialog reappears.



11-7

Electrode Design


Step 7 Trim the electrode to the desired shape.

Choose Mold Trim . . À

À

The Mold Trim dialog displays.

Set or the options shown below:

Á Â Ã

11-8

In the graphics window, select the electrode body just created .

Choose Apply.




Electrode Design


A Select Direction dialog displays.

Ä

Most likely, the initial result is the actual cavity shape, because that is the normal behavior for mold trim. We want an opposite shape, that of carbon electrodes that will burn the cavity contour into cavity steel.

Choose Flip Direction . . Ä

Choose OK.

Choose Cancel until all dialogs are closed.

Only one new component was created. You see two, because the electrode is a member of the prod subassembly, which is instanced twice. Step 8 Leave the assembly open. You will use it in the next activity. This completes Activity 11-1.



11-9

Electrode Design


Insert Electrode Design Approach

The MoldWizard Electrode module provides five design steps to define electrodes:

Create Envelope

Create Head

Create EWCS

Create Foot

Create Drawing

The designer must decide which features are to be included in the electrode. In some cases it will be possible to manufacture an electrode that includes all of the feature details, in other cases the electrode will require modification to make it practical to manufacture. If the modifications for manufacturing remove essential features, additional electrodes will be required to complete the removed features.

11-10




Electrode Design


Envelope The first modeling operation in deg an electrode is defining an envelope for the features to be formed. An Envelope is a solid body that fully contains the faces to be included on the electrode. The Envelope may be a block, cylinder or other suitable shape. Envelopes may be created using conventional interactive modeling methods; however, this is generally not necessary.

Working Part The envelope geometry can be created in the core, cavity, or any sub insert. A pull down list is provided for easy selection of the desired work part.

Definition Method The electrode envelope can be created by two methods, selecting extremity faces, or creating it at the WCS origin and specifying dimensions.

Shape Two shapes of envelopes are provided, box and cylinder. A bitmap image for the selected shape is displayed, and available parameters are presented for editing. As with other MoldWizard libraries, the Envelope library may be extended by editing the File and or the Database spreadsheet.



11-11

Electrode Design


Head Working Part Choose the core or cavity as work part.

Forming Method Trim by Parting Surface shapes the electrode head by parting surface trim. Trim by Sheet trims a selected envelope with a sheet body. Selection of target or tool is done by Selection Steps. Trim by Solid Face extends a selected tool face into a sheet used to trim the target solid. Subtraction performs a solid boolean subtraction. This is useful to avoid complex trim sequences by subtracting a copy of the core, or cavity from the envelope.

Selection Steps Select Envelope and Select Tool Object steps are available. In Trim by Parting Surface, the parting surface is selected automatically by choosing the tool step.

Extrude Edges to Sheet You can choose contiguous edges to create a sheet using this function. This is helpful when unwanted sections from the head need to be trimmed off. The dialogs shown below guide you in selecting the edges.

11-12




Electrode Design


EWCS The EWCS dialog allows you to create a coordinate system and a component part for an electrode. A reference point, relative to the work piece, is created in the electrode component. This point may be used for EDM positioning drawings and NC set-up purposes. The orientation of the coordinate system is the same as the WCS and its positioning is relative to a specified reference point. Working Part As with the other electrode dialogs, a choice of core or cavity part is offered to allow you to process several electrodes in different locations without leaving the electrode dialogs. Electrode Name The system will create a component part for each electrode using a default naming sequence. You can over ride the default by entering a name.



11-13

Electrode Design


Point Method Face Center Point creates the reference point in the middle of a selected face, generally the back face of the work piece. This method is suited for EDM positioning layouts that are dimensioned from the center of the workpiece. Point Subfunction will create the reference point at any specified position.

Displacement from Reference Point The values entered affect the position of the EWCS relative to NC setup for electrode manufacture. They do not affect EDM positioning because the coordinate system is defined relative to the electrode positioning reference point. Typically, rounded values are entered to make setup more intuitive for the NC operator.

Delete Available only in Edit mode, the Delete button deletes a selected EWCS and the corresponding electrode component part.

11-14




Electrode Design


Foot The electrode coordinate system must have already been created since the locating point of the foot is with respect to the origin of that coordinate system. The X and Y dimensions are measured from the foot locating point. Orientation of the foot is with respect to the EWCS as shown in bitmap. The interface for creating the foot is similar to the previously discussed Electrode Design dialogs. You control the Working Part. Standard shapes are available in a customizable library. Z-Level Adjust In edit mode, the selected foot is constrained to move in the Z direction only. The attachment face is trimmed or extended when the foot is relocated in Z, by an offset specified in a text input dialog:

Repositioning of the foot along the X and Y directions can be achieved by repositioning the electrode coordinate system, the EWCS. Delete The Delete button is available only in Edit mode. The selected foot is deleted, without affecting the head, component part, or EWCS.



11-15

Electrode Design


Drawing The Drawing dialog creates an automatic drawing for a selected electrode component. The reference point for electrode positioning is created on layer 200. To create a drawing for electrode positioning, include layer 200 as a visible layer. The remaining controls are the same as those offered in the Drawing Edit menu. They are presented in the electrode dialogs for convenience. Drawing Sheet Name You can over ride the default drawing sheet name by typing in a name of your choice. Units Metric (Si) or Inch units are selected by radio buttons. Size Standard sizes that reflect the current Units setting are available in a pull down list . Scale Controls the scale of the drawing. Projection Angle Third Angle Projection and First Angle Projection are available.

11-16




Electrode Design

Activity 11-2: Electrodes Using Envelope In this activity you will create the electrode used to burn a core profile for the two cavity tray mold. A staged assembly, if needed, can be found in: ... / moldwizd / electrode_2 / NOTE


Step 1 Open mdp_tray_top assembly file. Step 2 Initiate the Electrode Design Process.

Choose the Electrode icon.

The Electrode Design dialog opens.

Choose Insert Electrode . . À

À



11-17


Electrode Design


Choose Envelope.

The Envelope dialog opens. The cue line reads: Select bounding faces.

If necessary, set the Working Part to mdp_tray_core . . À

If necessary, set Definition Method to Bounding Faces . . Á

À Á

The Bounding Faces you need are the upper and lower faces of the core body that represent the highest and lowest points that will be formed by the electrode. You will need to add some additional stock all around the initial envelope.

11-18




Electrode Design


Select the two faces shown below:

Â

Ã

Â

Highest face on the part

Ã

Ribbon" face all around base of tray

Choose Apply in the Envelope dialog.

An envelope box appears on the core body. The dialog changes to Edit mode.

Edit the X, Y and Z values as shown below. Hint: Do not forget to press enter to apply each edit. X1 & X2 = 36 Y1 & Y2 = 65 Z1 & Z2 = 20

Choose Apply.

Choose Back in the Envelope dialog.



11-19

Electrode Design


The Electrode Design dialog reappears if you choose Back, but not if you Cancel. Step 3 Create the Electrode Head.

Choose Head.

The Head dialog opens, the Select Envelope step is active, and the cue reads: Select target bodies."

The target body is the solid body just created.

In the graphics window, select the envelope body.

Choose the Select Tool Object icon.

The parting body highlights in the graphics screen. The cue reads: Tool object selected."

Choose Apply.

The electrode is trimmed, and a Select Direction dialog opens. The trim direction needs to be reversed from the normal" trim for mold objects.

11-20




Electrode Design

Choose Flip Direction.

Choose OK.

Choose Back from the Head dialog.


The Electrode Design dialog reappears. Step 4 Define the Electrode Work Coordinate System (EWCS).

Choose EWCS.

The EWCS dialog opens, the Attach Face (On Head) step is active, and the cue reads: Select attach faces.



11-21

Electrode Design


The attach faces are the faces (or single face) on the electrode Head where the electrode Foot is to be attached. The electrode Foot will be attached to the EDM machine tool. A coordinate system based upon the Z level at the junction between the foot and the head will serve as a good reference when setting up the machine.

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

In the graphics screen, select the top face of the electrode Head, the solidly shaded face adjacent to the arrow.

Choose OK.

The Reference Point selection step is now active on the EWCS dialog. The cue reads: Select face to create reference point."

In the graphics screen, select the bottom face of the core insert body as shown shaded and crosshatched in the figure above.

The X, Y and Z Displacement fields become available.

11-22




Electrode Design


Set X_displacement = 0

Set Y_displacement = 0

Allow Z_displacement to remain at the default value.

Choose OK to create the EWCS.

The Electrode Design dialog reappears. Step 5 Create the Electrode Foot.

Choose Foot.



11-23

Electrode Design


The Foot dialog opens. The cue reads: Select linked body or EWCS."

The linked body referred to in the cue is an electrode Head.

Select the electrode Head or the EWCS.

Accept all dialog defaults by choosing OK.

An electrode Foot is added to the Head.

11-24




Electrode Design


The Electrode Design dialog reappears.



11-25

Electrode Design


Step 6 Create an Electrode Drawing.

Select Drawing. The Drawing dialog opens.

Set the drawing Size to A1 - 594 X 841 . . . À

À

Á

11-26

Choose OK . . Á




Electrode Design

A dimensioned drawing similar to the simplified illustration below is generated.

Cancel from the Electrode Design dialog.

Step 7 Save and Close all part files. This completes Activity 11-2.



11-27


Electrode Design

ÏÏÏ ÏÏÏ 11 ÏÏÏ ÏÏÏ SUMMARY

Electrode design is fast and easy with the Electrode Standard Part library. The envelope, head, and foot options offer more elaborate control, and have accompanying tools for creating set up reference coordinates and an automated drawing. In this lesson you:

11-28

Rapidly created an electrode design using the Insert Standard Part method.

Created an electrode design with set up data and a drawing using the Insert Electrode method.




Documentation

Documentation Lesson 12

PURPOSE

OBJECTIVES

In this lesson you will use MoldWizard utilities to document tooling assemblies.



Create an associative Bill of Materials for a MoldWizard tooling assembly.

Use MoldWizard Drafting to accelerate creation of Unigraphics drawings and drawing views.

This lesson contains the following activities. Activity

Page

12-1 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 12-2 Drafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19



12-1

Documentation

Bill of Materials This function provides a listing of standard parts used in a tooling assembly. The Bill of Materials function is a filter which works with the familiar Assemblies Parts List function to generate a fully customizable part attribute based Bill of Materials for your tooling assemblies.


For more information, consult help for Assemblies Parts List:

The Parts List Format resides in the top" seed parts.

The attributes defined in the format exist in all supplied standard parts and moldbase components.

The essential attributes required for supplied parts to work with the Bill of Materials are: UM_STANDARD_PART = 1

Part is in Standard Parts Only listing.

CATALOG = any value

Part appears in both types of listing.

Standard Parts Only

The Standard Parts Only option creates a parts list for only parts added with Standard Part Management. The parts all have the part attribute UM_STANDARD_PART = 1, and a CATALOG part attribute with any value.

12-2




Documentation

All Parts in Mold Assembly

All Parts in Mold Assembly includes mold base hardware in the parts list. These mold base parts have a CATALOG attribute. Parts such as the fill part, the shrink part, and the parting part do not have a CATALOG attribute. MoldWizard uses the presence of the CATALOG attribute to filter only parts that are relevant to a Bill of Materials.



12-3


Documentation

BOM Field Edit

BOM Field Edit provides a friendly interface to some common assemblies parts list functions.


For additional details, please consult the MoldWizard documentation. BOM Record Edit

12-4

a fully detailed BOM listing




Documentation

editing capability for certain parts list fields

six useful BOM list management functions


For additional details, please consult the MoldWizard documentation.



12-5

Documentation

Activity 12-1: Bill of Materials In this activity you will create an automatic Bill of Materials for a tray assembly. NOTE



Step 1 Open the top level assembly in the bom directory.

Navigate to /bom and open mdp_tray_top.

If necessary, activate Application Assemblies.


Step 2 Edit Bill of Material field sizes.

Choose the Bill of Material icon.

The BOM Design dialog opens.

À

12-6

Choose All Parts in Mold Assembly . . . À




Documentation

Choose BOM Field Edit . . À

À


Select any text in the DESCRIPTION row . . . Á

Á

Â The values appear in editing windows below the lists.

Type 20 in the Length window Â, and press Enter.



12-7

Documentation

Using the same procedure, make the following changes: CATALOG/SIZE . . . . . Length . . . 25 Stock Size . . . . . . . . . . . Length . . . 25


Ã After editing, the dialog should look like the example above.

12-8

Choose OK in the BOM Field Edit dialog . . . Ã




Documentation

Step 3 Edit Bill of Material predefined entries.

Choose BOM Record Edit . . . . À


À

Drag the BOM Record Edit dialog until it is wide enough that the horizontal scroll bar Á disappears, as shown below:

Á

The resulting dialog is too wide to illustrate on this page. We show only the most important portions of it.

Select item NO. 1 in the BOM Record Edit dialog . . . Â

Â The NO. 1 row highlights across all columns.



12-9

Documentation

Double-click in the DESCRIPTION field to highlight all existing text . . . Ã

Ã

Type Return Pin, Length = 99 and then press Enter . . . Ä


Ä The new description appears in the listing window when you press Enter . . . Å

Å

Use the same procedure to make the following edit: CATALOG SIZE . . . . . . . . STD Z 41 / 16 x 100

Step 4 Add Defined components to the Bill of Material.

12-10

Select the cavity insert from the graphics screen.




Documentation

A message dialog appears:


Choose OK in the message dialog.

Á À

Choose Apply in the BOM Record Edit dialog . . . À

A new record is added.

Choose Edit StockSize . . . Á

The displayed part changes.



12-11

Documentation

MoldWizard calculates the size of the solid body in the part you selected and displays a dialog for your input.


Choose OK in the Stock Size dialog . . .

Edit fields as follows. Be sure to press Enter after each edit: SUPPLIER . . . . . . . . . . . . . EDS PLM Solutions DESCRIPTION . . . . . . . . . Cavity Insert MATERIAL . . . . . . . . . . . . H-13

Select the core insert in the graphics window and add it to the list.

Edit the data fields as shown below:

SUPPLIER . . . . . . . . . . . . . EDS PLM Solutions DESCRIPTION . . . . . . . . . Core Insert MATERIAL . . . . . . . . . . . . H-13

12-12




Documentation

Step 5 Export Bill of Material data to an Excel spreadsheet.

Choose Export Excel . . À

À

When prompted, type mdp_tray . . . Á

Choose OK . . Â

Á


Â

When prompted, choose Enable Macros.

Examine the data that was exported.

Step 6 Close all files.

Choose File Exit from Excel.

Cancel from any open dialogs.

Choose File Close All Parts. This concludes activity 12-1.



12-13

Documentation

Mold Drawing The Mold Drawing function automates the initial set up of drawings for further work with standard Unigraphics drafting functions.


create drawings

import predefined border patterns to the drawing

create views

hide components in each view

create balloons for components in each view.

NOTE

For all drafting functions, please consult MoldWizard documentation for details.

Title Block tab The title block function, drawing borders, and several preferences require set up and customization according to your standards and desired methods of working.

12-14




Documentation

Drawing tab


Default templates correspond to the units of the tooling assembly.

Optionally select English or Metric, to use different units.

Choose an existing template.

Optionally change the default drawing name.

Choose Apply.



12-15

Documentation

Visibility tab


12-16

To provide control of the visibility of each component by the side of the mold and the type of component, two attributes may be assigned to identify each component: "SIDE" and "TYPE."

Select components from the list, graphics screen, or Assembly Navigator.

Choose an Attribute Name and Attribute Value.

Choose Assign Attribute to assign the specified attribute to all of the selected components.




Documentation

View tab


The list of views and scales are taken from the drawing template.

Select a view, choose visibility options, and Apply.

The default values for Visibility Control are as follows:

Core View . . . . . Show B Side" is toggled on Cavity View . . . . Show A Side" is toggled on Front Section . . . Show A Side" and "Show B Side" are toggled on Right Section . . . Show b Side" and "Show A Side" are toggled on



12-17

Documentation

Balloon tab


NOTE

12-18

Before placing the Parts List and Balloons in the drawing, the Part List must be generated by MoldWizard BOM.

Automatic Placement is completed by choosing the Auto Placement icon.

Specify Origin is completed by choosing the Specify Origin icon and indicating a point on the graphics screen.




Documentation

Activity 12-2: Drafting In this activity you will prepare basic drawing views, NOTE


Step 1 Open the top level assembly from the drafting directory.

Navigate to /drafting and open mdp_tray_top.

If necessary, activate Application Assemblies.



Step 2 Create a Mold Drawing.

Choose the Mold Drawing icon.

that Drawings is set to Create New . . . À

Type LAYOUT1 in the Drawing Sheet Name window . . Á

À Á

Â

Accept the default template selection Â by choosing OK.



12-19

Documentation

Step 3 Display the drawing.

NOTE


Choose Application Drafting.

The are two possibilities. Either a drawing view displays, or the tooling geometry continues to be displayed. We want to see the drawing.

If necessary, choose Drawing Display Drawing.

Choose Mold Drawing in the MoldWizard toolbar.

On the Drawing tab, that LAYOUT1 is selected . . À

À Step 4 Assign Visibility Attributes.

Choose the Visibility tab.

The display changes back to the model display. This is necessary to permit screen selections for Visibility options.

that Attribute Name is Side . . Á and Attribute Value is A . . Â

Á Â

12-20

If necessary, Orient the view to Front.




Documentation

The prompt reads Select/Choose components."

NOTE

Drag to select all components in the fixed half . . . . Ã

Be careful not to drag over the core inserts . . . Ä

Ã

Ã

Ä


Ä

FRONT View - Selecting Fixed Half Components



12-21

Documentation


Å

12-22

Choose Assign Attribute . . Å




Documentation

Change the Attribute Value to B . . . Æ

Æ Æ

Drag to select lower half component in two stages, as shown below . . . ÇÈ

È Ç

È

Ç

FRONT View - Selecting Moving Half Components

Choose Assign Attribute.

Step 5 Create Views for the Mold Drawing.

Choose the View tab.



12-23


Documentation

that CORE is highlighted . . . À

that under Side, Show B is ON . . . Á

À

ÏÏÏ 12 ÏÏÏ ÏÏÏ ÏÏÏ Á

Â

Choose Apply . . Â

A plan view of the B or core half appears.

12-24




Documentation

Choose CAVITY . . . Ã

that Show A is ON . . . Ä


Ã

Ä

Choose Apply.

A plan view of the A or Cavity half appears.

Choose FRONTSECTION.

that Show A and Show B are both ON.

Choose Apply.

The prompt reads Define Cut position."



12-25

Documentation

Å


12-26

Choose Point Sub Function . . . Å

Choose Arc/Ellipse/Sphere Center:




Documentation

Select the sprue puller pin arc in the core half plan view for the Cut Position . . . Æ 14

13

12

11

J


I

H

Æ G

F

Choose OK in the Point Constructor dialog.

Choose OK in the Section Line Creation dialog.

A Front Section View appears. Processing continues until components are cross hatched, and continues further as the system automatically clocks the cross hatch angles.

Choose RIGHTSECTION.

that Show A and Show B are both ON.

Choose Apply.

Choose Point Sub Function.




12-27

Documentation

Select any of the 4.5 dia pin arcs in the core half plan view for the Cut Position . . ³ 14

13

12

11

J


I

Ç H

G

F

12-28

Choose OK in the Point Constructor dialog.

Choose OK in the Section Line Creation dialog.




Documentation

A Right Section View appears. 14

13

12

11

10

9

8

7

6

5

4

G

J

3

REV: NEW

2 DATE: 00/00/01

CHANGE:

1 REASON:

J

Ä

I

F

Á

À

G

G

Æ

F

G

Â

E

Ã

F

E

D

D

C

C

B

B

Å

A

14

13

12

11

10

9

8

À

Plan View, Core

Á

Plan View, Cavity

Â

Front Section View

Ã

Right Section View

Ä

Revision Block

Å

Title Block

Æ

Border

7


6

5

4

DATE:00/00/01

H


PROJECT NUMBER:PROJECT NUMBERCUSTOMER: CUSTOMER

F

PART NAME 1: PART NAME 1

H

I

TOLERANCES(METRIC):DESCRIPTION: DESCRIPTION_1 (UNLESS SPECIFIED) DESCRIPTION_2 A LINEAR: PROJECT NUMBER: PROJ CUSTOMER:CUSTOMER X= .5 DESIGNED BY: DESIGNER APPROVED:______ DATE: 00/00/01 X.X= CAD FILE: PART NAME .1 X.XX= .02 SOFTWARE/VERSION:UG/V17.02.2 SCALE: 1:1 SHEET 1 OF 1 X.XXX= .01 PART NAME: PART NUMBER: MATERIAL: SHRINK: CAVS: PART NUMBER 1 MATERIAL_1 .000/1 ANGULAR: 1 PART NAME 1 CAV 1 2 PART NAME 2 PART NUMBER 2 MATERIAL_2 .000/1 CAV 2 XX= 1 X.X= 1/2 PART NUMBER 3 MATERIAL_3 .000/1 CAV 3 3 PART NAME 3 X.XX= 1/4 4 PART NAME 4 PART NUMBER 4 MATERIAL_4 .000/1 CAV 4 3 2 1


12-29

Documentation

Step 6 Add Bill of Material to Mold Drawing.

Choose the Balloon tab.

Choose Create Part List . . . À


À

Choose End Point in the Point Constructor dialog . . Á

Á

12-30




Documentation

Choose the End Point of the title block line illustrated . . . Â

Â


The BOM note appears:



12-31

Documentation

NOTE


When the BOM note overlaps a view, you have several choices:

Rearrange the views

Edit field widths, if possible

Activate text fitting options in Assemblies → Parts List

Change the drawing size

Choose Assemblies Parts List.

Modify Header to Below . . Â

Â

Ã

12-32

Choose Recreate . . . Ã




Documentation

Step 7 Add Detail Balloons to Mold Drawing.

If necessary, reopen the MoldWizard Create/Edit Mold Drawing dialog, at the Balloon tab.

that Snap to Margin is OFF . . À


À

Select any edge in either section view.

Choose Specify Origin . . Á

Á

Move cursor to the desired balloon location.

Click to indicate the position.

Choose Automatic Placement . . . Â

Â

Select edges from a few other components.



12-33

Documentation

Step 8 Edit Title Block Data of Mold Drawing Template.

Choose File Properties.

Choose the Attributes tab . . À

À


Scroll down to and select the DESIGNER Title . . . Á

Á

Â Ã

Edit the Value to your own name press Enter . . . . Â

Choose Cancel in the Part Properties dialog . . Ã

that the designer name changed in the Title Block.

Step 9 Choose File Close Save All and Close. This concludes activity 12-2.

12-34




Documentation

SUMMARY

MoldWizard provides the Mold Drawing functions to accelerate drawing production by streamlining the most common functions. Additional drafting skills can be easily acquired via CAST.


In this lesson you:

Created and customized a Bill of Materials

Created a multi-view drawing

Added the BOM to your drawing

Modified Title Block information



12-35

Documentation

ÏÏÏ 12 ÏÏÏ ÏÏÏ ÏÏÏ (This Page Intentionally Left Blank)

12-36




Additional Activities


ÏÏÏ ÏÏÏ A ÏÏÏ ÏÏÏ

Appendix A


Page

A-1

Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

A-2

Bulb Housing . . . . . . . . . . . . . . . . . . . . . . . . . A-3

A-3

Power Tool Casing . . . . . . . . . . . . . . . . . . . . . A-4

A-4

Pager Holster . . . . . . . . . . . . . . . . . . . . . . . . . A-5

A-5

Snap Lock Tab . . . . . . . . . . . . . . . . . . . . . . . . A-6

A-6

Cell Phone Case . . . . . . . . . . . . . . . . . . . . . . . A-7

A-7

Phone Jack Case . . . . . . . . . . . . . . . . . . . . . . A-8

A-8

Steam Iron Case . . . . . . . . . . . . . . . . . . . . . . A-9

A-9

Utility Saw Case . . . . . . . . . . . . . . . . . . . . . . . A-10

A-10

Sprinkler Housing Cap . . . . . . . . . . . . . . . . . A-11

A-11

Patch Example with Negative Offset . . . . . . . A-12

A-12

Engine Casting . . . . . . . . . . . . . . . . . . . . . . . . A-19

A-13

Cast Bracket . . . . . . . . . . . . . . . . . . . . . . . . . A-20

A-14

Forged Wrench . . . . . . . . . . . . . . . . . . . . . . . A-21

A-15

Game Controller . . . . . . . . . . . . . . . . . . . . . . A-22

A-16

Coffee Filter Holder . . . . . . . . . . . . . . . . . . . A-23

A-17

Spray Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

A-18

Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A-25



A-1



Activity A-1: Flange

This part, flange/mdp_flange, requires slides to form two holes, one in each of two bosses at the left side in the above illustration. No explicit steps are provided. This concludes activity A-1.

A-2



MoldWizard V18.0.3 Unigraphics V18.0.3.2.



Activity A-2: Bulb Housing

There are no explicit steps provided for this light bulb housing, housing/mdp_housing This concludes activity A-2.



A-3



Activity A-3: Power Tool Casing

There are no explicit steps provided for this part, case2/mdp_case2 This concludes activity A-3.

A-4






Activity A-4: Pager Holster

There are no explicit steps provided for this part, case3/mdp_case3 This concludes activity A-4.



A-5



Activity A-5: Snap Lock Tab

There are no explicit steps provided for this part, loctab/mdp_loctab The part provides practice in creating and trimming a patch block. This concludes activity A-5.

A-6






Activity A-6: Cell Phone Case

There are no explicit steps provided for this part, phone/mdp_phone The part should provide good experience in patching procedures. This concludes activity A-6.



A-7



Activity A-7: Phone Jack Case

There are no explicit steps provided for this part, connhsg/mdp_connhsg This concludes activity A-7.

A-8






Activity A-8: Steam Iron Case

There are no explicit steps provided for this part, iron/mdp_iron It should provide some interesting decisions about parting construction and patch up. This concludes activity A-8.



A-9



Activity A-9: Utility Saw Case

There are no explicit steps provided for this part, sawcover/mdp_sawcover This concludes activity A-9.

A-10






Activity A-10: Sprinkler Housing Cap

There are no explicit steps provided for this part, sprinkler_cap/mdp_sprkcap This part provides practice in patch body construction. The thread face" at the bottom of each slot" is uniquely positioned. You can either:

construct six patch blocks

find the largest block

construct a patch block and trim it

make a circular array

trim each instance at the thread face only

or

The second approach is only useful if it is known that the part is symmetrical and will remain that way. This product is useful to practice electrode construction, for the small pockets. This concludes activity A-10.



A-11



Activity A-11: Patch Block with Negative Offset

The following part has a complex contour. This geometry lends itself to demonstrating an unusual but powerful method for trimming a patch body. Step 1 Create a project for tab/mdp_tab

Step 2 Create a Mold Tooling Insert. The WCS is not suitable.

A-12

Choose WCS → Orient WCS → X-Axis, Y-Axis.





First, select this edge, at this end. The first pick determines XC+

Second, select this edge, at this end. The second pick determines the side of the X axis for YC+.

This is the WCS orientation you want to achieve.

Select the two edges shown above, in the suggested order and at the end points indicated.

When the WCS is oriented as shown above, accept it as the mold coordinate system by choosing the Mold CSYS icon:

Choose the Shrinkage icon:

Enter Uniform Scale factor 1.008. In the graphics window select the solid body, then choose OK.

Choose the Work Piece icon:

Accept the default values for the work piece by choosing OK.

Choose the MoldWizard Tools icon:



A-13



As the mold maker analyses the job, contours at the window opening cause a flurry of mental activity.


Clearly we need to shut off to the underside of the hook" shape. The shut off will have to extend through the window to the flat face under the hook, labelled as the Horizontal Shut Off" in the figure below. We also notice that the designer has been kind enough to create natural shut off faces in a plane traversing the height of the hook", labelled as the Vertical Shut Off".

ÏÏÏÏÏ ÏÏÏÏÏ

Horizontal Shut Off

Vertical Shut Off

The faces of the opening are positioned in an irregular pattern with respect to the WCS. It will be easier to pick several faces to define the patch block than to guess exactly which faces would yield an optimum result. The irregularity of the opening makes it impossible to use all of the faces as individual trim sheets. The complexity of free form trim methods required is daunting. A solid based approach to shaping the block is indicated. We decide to create a patch block, use a couple of Surface Split operations to create the two important shut off faces on the patch body, then use subtract to capture the contours of the window opening in one operation. For our grand finale we will employ offset in an unusual way to extend the window walls, formed by our solid subtract, to the shut off face.

A-14





Step 3 Create a box for a patch body.

Create Box, Allowance 2.5.

Select the at least the three faces shown.


À

Â

Á

The patch block should completely enclose the window and hook" faces. Step 4 Trim to the two primary shut off faces.


Select and confirm the patch block as the solid to be split.

One by one, trim to the two faces shown below.



A-15



ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ

Á Horizontal Shut Off

À Vertical Shut Off

Step 5 Use Subtract to quickly produce the window contours in the patch block.

Choose Subtract.

Select and confirm the green patch block as the target solid.

Select the orange parting body as the tool solid.

The dark lines in the illustration above show the patch body after a system generated copy of the shrink part has been subtracted from it. The lighter lines represent the hook" shape in the shrink part.

A-16





Step 6 Use modeling Offset Face to complete the patch shape.

NOTE


From the Menu Bar choose Application Modeling.

Choose the Offset Faces icon:

In the Enter Parameters dialog enter -7.5 as the Offset Value, then choose OK.

Do not omit the minus sign!

Choose Offset Faces.

Select and confirm the face shown below, then choose OK to end selection.

The face is offset upwards into the patch body, removing unwanted material!

Choose Cancel from the Enter Parameters dialog.



A-17


How Does it Work?


The Offset Faces function has the property that faces surrounding the offset face are trimmed smaller or larger using their natural" parameterization. The faces on the window have taper. Using Offset extends these faces to create a shut off that blends in perfectly with the faces on the part. The same result could NOT be achieved by Profile Split. NOTE

This method will not work if the face being offset has an internal loop. Notice in the illustration that the original face, although very irregular, has a single edge loop, roughly following the outline of a U".

Step 7 Patch the opening.

Solid Patch, using the orange body as target, and the green patch body as tool.

After the core body is constructed, unite a copy of the patch body to complete the shut off. Step 8 Save your work.


This concludes activity A-11.

A-18






Activity A-12: Engine Casting

There are no explicit steps provided for this part, engine/mdp_engine This concludes activity A-12.



A-19



Activity A-13: Cast Bracket

There are no explicit steps provided for this part, bracket/mdp_bracket This concludes activity A-13.

A-20






Activity A-14: Forged Wrench

There are no explicit steps provided for this part, wrench/mdp_wrench This concludes activity A-14.



A-21



Activity A-15: Game Controller

There are no explicit steps provided for this part, game/mdp_gamectrl This concludes activity A-15.

A-22






Activity A-16: Coffee Filter Holder

There are no explicit steps provided for this part, coffee/mdp_coffee This concludes activity A-16.



A-23



Activity A-17: Spray Cap

There are no explicit steps provided for this part, spray_cap/mdp_sprcap This concludes activity A-17.

A-24






Activity A-18: Cover Plate

There are no explicit steps provided for this part, cover_plate/mdp_plate This concludes activity A-18.



A-25




A-26




Glossary

Glossary

ABS - Absolute coordinate system. Absolute Coordinate System - Coordinate system in which all geometry is located from a fixed or absolute zero point. active view - One of up to 49 views per layout in which you can directly work. angle - In Unigraphics, an angle measured on the XĆY plane of a coordinate system is positive if the direction that it is swept is counterclockwise as viewed from the positive Z axis side of the XĆY plane. An angle swept in the opposite direction is said to be negative. arc - An incomplete circle; sometimes used interchangeably with the term circle." ASCII - American Standard Code for Information Interchange. It is a set of 8Ćbit binary numbers representing the alphabet, punctuation, numerals, and other special symbols used in text representation and communications protocol. aspect ratio - The ratio of length to height which represents the change in size of a symbol from its original. assembly - A collection of piece parts and subĆassemblies representing a product. In Unigraphics, an assembly is a part file which contains components. assembly part - A Unigraphics part file which is a Ćdefined, structured combination of subĆassemblies, components and/or objects. associativity - The ability to tie together (link) separate pieces of information to aid in automating the design, drafting, and manufacture of parts in Unigraphics. attributes - Pieces of information that can be associated with Unigraphics geometry and parts such as asg a name to an object. block font - A Unigraphics character font which is the default font used for creating text in drafting objects and dimensions. body - Class of objects containing sheets and solids (see solid body and sheet body). bottomĆup modeling - Modeling technique where component parts are designed and edited in isolation of their usage within some higher level assembly. All assemblies using the component are automatically updated when opened to reflect the geometric edits made at the piece part level.



GL-1

ÉÉÉ GL ÉÉÉ ÉÉÉ


Glossary

boundary - A set of geometric objects that describes the containment of a part from a vantage point. CAD/CAM - Computer Aided Design/Computer Aided Manufacturing. category, layer - A name assigned to a layer, or group of layers. A category, if descriptive of the type of data found on the layers to which it is assigned, will assist the in identifying and managing data in a part file. chaining - A method of selecting a sequence of curves which are ed endĆtoĆend. circle - A complete and closed arc, sometimes used interchangeably with the term arc." component - A collection of objects, similar to a group, in an assembly part. A component may be a subĆassembly consisting of other, lower level components. component part - The part file or master" pointed to by a component within an assembly. The actual geometry is stored in the component part and referenced, not copied, by the assembly. A separate Unigraphics part file that the system associates with a component object in the assembly part. cone direction - Defines the cone direction using the Vector Subfunction. cone origin - Defines the base origin using the Point Subfunction. half angle - The half vertex angle defines the angle formed by the axis of the cone and its side. constraints - Refer to the methods you can use to refine and limit your sketch. The methods of constraining a sketch are geometric and dimensional. construction points - Points used to create a spline. Construction points may be used as poles (control vertices), defining points, or data points. See POLES, DEFINING POINTS, and DATA POINTS. control point - Represents a specific location on an existing object. A line has three control points: both end points and the midpoint of the line. The control point for a closed circle is its center, while the control points for an open arc are its end and midpoints. A spline has a control point at each knot point. A control point is a position on existing geometry. Any of the following points: 1. Existing Points 2. Endpoints of conics 3. Endpoints and midpoints of open arcs 4. Center points of circles 5. Midpoints and endpoints of lines 6. Endpoints of splines. convert curve - A method of creating a bĆcurve in which curves (lines, arcs, conics or splines) may be selected for conversion into a bĆcurve.

GL-2




Glossary

Coordinate System - A system of axes used in specifying positions (CSYS). counterclockwise - The rightĆhand rule determines the counterĆ clockwise direction. If the thumb is aligned with the ZC axis and pointing in the positive direction, counterclockwise is defined as the direction the fingers would move from the positive XC axis to the positive YC axis. current layout - The layout currently displayed on the screen. Layout data is kept in an intermediate storage area until it is saved. curve - A curve in Unigraphics is any line, arc, conic, spline or bĆcurve. A geometric object; this may refer to a line, an arc, a conic, or a spline. defaults - Assumed values when they are not specifically defined. defining points - Spline construction points. Splines created using defining points are forced to through the points. These points are guaranteed to be on the spline. degreeĆofĆfreedom arrows - ArrowĆlike indicators that show areas that require more information to fully constrain a sketch. design in context - The ability to directly edit component geometry as it is displayed in the assembly. Geometry from other components can be selected to aid in the modeling. Also referred to as edit in place. dimensional constraint - This is a scalar value or expression which limits the measure of some geometric object such as the length of a line, the radius of an arc, or the distance between two points. directory - A hierarchical file organization structure which contains a list of filenames together with information for locating those files. displayed part - The part currently displayed in the graphics window. edit in place - See design in context. emphasize work part - A color coding option which helps distinguish geometry in the work part from geometry in other parts within the same assembly. endpoint - An endpoint of a curve or an existing point. expression - An arithmetic or conditional statement that has a value. Expressions are used to control dimensions and the relationships between dimensions of a model. face - A region on the outside of a body enclosed by edges.



GL-3



Glossary

feature - An allĆencoming term which refers to all solids, bodies, and primitives. file - A group or unit of logically related data which is labeled or named" and associated with a specified space. In Unigraphics, parts, and patterns are a few types of files. filtering - See object filtering. font box - A rectangle or box" composed of dashed line objects. The font box defines the size, width and spacing of characters belonging to a particular font. font, character - A set of characters designed at a certain size, width and spacing. font, line - Various styles of lines and curves, such as solid, dashed, etc. free form feature - A body of zero thickness. (see body and sheet body) generator curve - A contiguous set of curves, either open or closed, that can be swept or revolved to create a body. geometric constraint - A relationship between one or more geometric objects that forces a limitation. For example, two lines that are perpendicular or parallel specifies a geometric constraint. grid - A rectangular array of implied points used to accurately align locations which are entered by using the screen position" option. guide curve - A set of contiguous curves that define a path for a sweep operation. virtual intersection - Intersection formed by extending two line segments that do not touch to the position that they cross. The line segments must be nonĆparallel and coplanar. inflection - A point on a spline where the curve changes from concave to convex, or vice versa. interactive step - An individual menu in a sequence of menus used in performing a Unigraphics function. isometric view (TfrĆISO) - Isometric view orientation - one where equal distances along the coordinate axes are also equal to the view plane. One of the axes is vertical. knot points - The defining points of a spline. Points along a BĆspline, representing the endpoints of each spline segment.

GL-4




Glossary

layer - A layer is a partition of a part. Layers are analogous to the transparent material used by conventional designers. For example, the may create all geometry on one layer, all text and dimensions on a second, and tool paths on a third. layout - A collection of viewports or window areas, in which views are displayed. The standard layouts in Unigraphics include one, two, four or six viewports. layouts - Standard layouts are available to the . These include: L1 - Single View, L2 - Two Views, L3 - Two Views, L4 - Four Views, L6 - Six Views.


Information window - The window used in listing operations, such as Info. loaded part - Any part currently opened and in memory. Parts are loaded explicitly using the File→Open option and implicitly when they are used in an assembly being opened. menu - A list of options from which the makes a selection. model space - The coordinate system of a newly created part. This is also referred to as the absolute coordinate system." Any other coordinate system may be thought of as a rotation and/or translation of the absolute coordinate system. name, expression - - The name of an expression is the single variable on the left hand side of the expression. All expression names must be unique in a part file. Each expression can have only one name. See expression. objects - All geometry within the Unigraphics environment. offset face - A Unigraphics surface type created by projecting (offsetting) points along all the normals of a selected surface at a specified distance to create a true" offset. options - A number of various alternatives (functions, modes, parameters, etc.) from among which the can choose. origin - The point X = 0, Y = 0, Z = 0 for any particular coordinate system. parametric design - Concept used to define and control the relationships between the features of a model. Concept where the features of the model are defined by parameters. part - A Unigraphics file containing a .prt extension. It may be a piece part containing model geometry, a subĆassembly, or a topĆlevel assembly.



GL-5


Glossary

part or model - A collection of Unigraphics objects which together may represent some object or structure. partially loaded part - A component part which, for performance reasons, has not been fully loaded. Only those portions of the component part necessary to render the higher level assembly are initially loaded (the reference set). point set - A distribution of points on a curve between two bounding points on that curve. Point Subfunction Menu - A list of options (methods) by which positions can be specified in Unigraphics. readĆonly part - A part for which the does not have write access privilege. real time dynamics - Produces smooth pan, zoom, and rotation of a part, though placing great demand on the U. Refresh - A function which causes the system to refresh the display list on the viewing screen. This removes temporary display items and fills in holes left by Blank or Delete. rightĆhand rule, conventional - The rightĆhand rule is used to determine the orientation of a coordinate system. If the origin of the coordinate system is in the palm of the right fist, with the back of the hand lying on a table, the outward extension of the index finger corresponds to the positive Y axis, the upward extension of the middle finger corresponds to the positive Z axis, and the outward extension of the thumb corresponds to the positive X axis. rightĆhand rule for rotation - The rightĆhand rule for rotation is used to associate vectors with directions of rotation. When the thumb is extended and aligned with a given vector, the curled fingers determine the associated direction of rotation. Conversely, when the curled fingers are held so as to indicate a given direction of rotation, the extended thumb determines the associated vector. screen cursor (cursor) - A marker on the screen which the moves around using some position indicator device. Used for indicating positions, selecting objects, etc. Takes the form of a fullĆscreen cross. sheet - A object consisting of one or more faces not enclosing a volume. A body of zeroĆthickness. Also called sheet body.) sketch - A collection of geometric objects that closely approximates the outline of a particular design. You refine your sketch with dimensional and geometric constraints until you achieve a precise representation of your design. The sketch can then be extruded or revolved to obtain a 3D object or feature.

GL-6




Glossary

Sketch Coordinate System (SCS) - The SCS is a coordinate system which corresponds to the plane of the sketch. When a sketch is created the WCS is changed to the SCS of the new sketch. solid body - An enclosed volume. A type of body (see Body). spline - A smooth freeĆform curve. stored layout - The last saved version of a layout. stored view - The last saved version of a view. string - A contiguous series of lines and/or arcs connected at their end points. subĆassembly - A part which both contains components and is itself used as a component in higherĆlevel assemblies. surface - The underlying geometry used to define a face on a sheet body. A surface is always a sheet but a sheet is not necessarily a surface (see sheet body). The underlying geometry used to define the shape of a face on a sheet. system - The Unigraphics System. temporary part - An empty part which is optionally created for any component parts which cannot be found in the process of opening an assembly. topĆdown modeling - Modeling technique where component parts can be created and edited while working at the assembly level. Geometric changes made at the assembly level are automatically reflected in the individual component part when saved. trim - To shorten or extend a curve. trimetric view (TfrĆTri) - A viewing orientation which provides you with an excellent view of the principal axes. In Unigraphics II, the trimetric view has the ZĆaxis vertical. The measure along the XĆaxis is 7/8 of the measure along Z, and the measure along the YĆaxis is 3/4 of the measure along Z. Unigraphics - A computer based turnkey graphics system for computerĆaided design, drafting, and manufacturing, produced by UGS. units - The unit of measure in which you may work when constructing in Unigraphics. Upon log on, you may define the unit of measure as inches or millimeters. upgraded component - A component which was originally created preĆV10 but has been opened in V10 and upgraded to remove the duplicate geometry.



GL-7



Glossary

version - A term which identifies the state of a part with respect to a series of modifications that have been made to the part since its creation. view - A particular display of the model. View parameters include view orientation matrix; center; scale; X,Y and Z clipping bounds; perspective vector; drawing reference point and scale. Eight standard views are available to the : Top, Front, Right, Left, Bottom, Back, TfrĆISO (topĆfrontĆright isometric), and TfrĆTri (topĆfrontĆright trimetric). view dependent edit - A mode in which the can edit a part in the current work view only. view dependent modifications - Modifications to the display of geometry in a particular view. These include erase from view and modify color, font and width. view dependent geometry - Geometry created within a particular view. It will only be displayed in that view. WCS - Work Coordinate System. WCS, work plane - The WCS (Work Coordinate System) is the coordinate system singled out by the for use in construction, verification, etc. The coordinates of the WCS are called work coordinates and are denoted by XC, YC, ZC. The XCĆYC plane is called the work plane. Work Coordinate System - See WCS. work layer - The layer on which geometry is being constructed. You may create objects on only one layer at a time. work part - The part in which you create and edit geometry. The work part can be your displayed part or any component part which is contained in your displayed assembly part. When displaying a piece part, the work part is always the same as the displayed part. work view - The view in which work is being performed. When the creation mode is view dependent, any construction and view dependent editing that is performed will occur only in the current work view. XC axis - XĆaxis of the work coordinate system. YC axis - YĆaxis of the work coordinate system. ZC axis - ZĆaxis of the work coordinate system.

GL-8




Index

Index A ABS, GL-1 Absolute Coordinate System, GL-1 Active View, GL-1 Add Transition Points, 5-10 Angle, GL-1 Arc, GL-1 ASCII, GL-1 Aspect Ratio, GL-1 Assemblies, GL-1 Associativity, GL-1 Attribute, GL-1 Auto Cavity Core, 5-41 Auto Center, 4-15 Auto Patch, 3-19 Auto Process, 5-2 Auto Search Parting Lines, 5-4 Auto Transition Objects, 5-9

B Bill of Materials All Parts in Mold Assembly, 12-3 BOM Field Edit, 12-4 BOM Record Edit, 12-4 Overview, 12-2 Standard Parts Only, 12-2 Body, GL-1 Bottom-Up Modeling, GL-1 Boundary, GL-2

C Category, Layer, GL-2 Cavity_Core, 5-68

Circle, GL-2 Circular Layout, 4-9 Cloning Process, 2-4 Product Sub Assembly, 2-9 Project Assembly, 2-8 Component, GL-2 Part, GL-2 Cone Direction, GL-2 Origin, GL-2 Constraints, GL-2 Construction Points, GL-2 Control Point, GL-2 Convert, Curves to BĆCurves, GL-2 Cooling, 10-2 Channel Design, 10-19 Component Design, 10-3 Coordinate Systems, GL-3 Sketch, GL-7 Core & Cavity, 5-68 Check Geometry, 5-68 Check Overlapping, 5-68 Create Cavity, 5-68 Create Core, 5-68 Counterclockwise, GL-3 Create Box, 3-28 Create Cavity, 5-68 Create Core, 5-68 Create Parting Surfaces, 5-31 Bounded Plane, 5-33 Distance, 5-30 parting_extrude_distance, 5-30 Enlarged Surface, 5-37 Extrude, 5-32 Extrude Direction, 5-32 Skip, 5-32 Swept, 5-36 Tolerance, 5-30 Create Patch Block, 3-28 Create Box, 3-28 Current Layout, GL-3 Cursor, GL-6 Curve, GL-3

D

Chaining, GL-2 Check Geometry, 5-68 Check Overlapping, 5-68

ÉÉÉ IN ÉÉÉ ÉÉÉ

Default File Settings MW_CoolingChannelL ayer, 10-37



IN-1


Index MW_CoolingPathLayer, 10-31 MW_DefaultsUnit, 2-28 MW_GateReferenceDisplay, 9-4 MW_HideObjectLayer, 3-34, 3-50, 5-22, 6-11 MW_InsertHeadLayer, 8-10 MW_PartingAutoProcess, 5-2 MW_PartingCavityL ayer, 8-21 MW_PartingCavitySurfL ayer, 5-67, 6-11 MW_PartingCavitySurfL ayerName, 5-67 MW_PartingCoreSurfL ayer, 5-67, 6-11 MW_PartingCoreSurfL ayerName, 5-67 MW_PartingLinesColor, 5-21 MW_PartingLinesLayer, 3-51 MW_PartingLinesLayerName, 3-51 MW_PartingMeshSurf, 3-26 MW_PartingPatchBodyLayer, 3-36 MW_PartingRegionType, 5-67 MW_PartingTransitObjectColor, 5-28 MW_ProductNameFirstDelimiter, 2-7 MW_ProductNameSecondDelimiter, 2-7 MW_ProjectInitialUnit, 2-2 MW_ProjectNameDelimiter, 2-7 MW_ToolsPatchFeatureNum, 3-26 MW_WorkPieceLayer, 2-28 MW_WorkPieceLayerName, 2-28 MW_WorkPieceOffset, 2-28 Defaults, GL-3 Defining Points, GL-3 DegreeĆofĆfreedom Arrows, GL-3 Design in Context, GL-3 Dimension Constraints, GL-3 Direction, Cone, GL-2 Directory, GL-3

Envelope, 11-11 Definition Method, 11-11 Shape, 11-11 Working Part, 11-11 EWCS, 11-13 Delete, 11-14 Displacement from Reference Point, 11-14 Electrode Name, 11-13 Point Method, 11-14 Working Part, 11-13 Foot, 11-15 Delete, 11-15 Z-Level Adjust, 11-15 Head, 11-12 Extrude Edges to Sheet, 11-12 Forming Method, 11-12 Subtraction, 11-12 Trim by Parting Surface, 11-12 Trim by Sheet, 11-12 Trim by Solid Face, 11-12 Selection Steps, 11-12 Working Part, 11-12 Legacy Method, 11-10 Emphasize Work Part, GL-3 Endpoint, GL-3 Enlarge Surface, 3-56 Envelope, Sub-insert, 8-4 Definition Method, 8-4 Shape, 8-4 Working Part, 8-4 Existing Surface, 3-18 Expressions, GL-3 Names, GL-5 Extract Regions, 5-65

Displayed Part, GL-3

F

E

Face, GL-3

Edge Patch, 3-16 Edit in Place, GL-3 Edit Parting Lines, 5-6 Edit Parting Surfaces, 5-40 Edit Transition Objects, 5-9 Ejector Pin Postprocessing, 7-26 Adjust Parameters, 7-27 Overview, 7-3 Sheet Trim, 7-28 Untrim, 7-28 Electrode Drawing, 11-16

IN-2


Family Mold, 4-2 Remove Family Member, 4-3 Features, GL-4 File, GL-4 Filtering, GL-4 Font Box, GL-4 Character, GL-4 Line, GL-4 Foot, Sub-insert, 8-7 Copy Sub-insert Component, 8-8 Foot List, 8-8 Sub-insert Part Name, 8-7



Index Free Form Feature, GL-4

Model Space, GL-5

Gate, 9-3 Gate Point Indication, 9-5

Mold Base Management, 6-2 Bitmap, 6-5 Catalog, 6-4 Index, 6-5 Rotate Mold Base, 6-6 Type, 6-4

Generator Curve, GL-4

Mold Csys, 2-15

Geometric Constraint, GL-4

Mold Drawing, 12-14 Balloon tab, 12-18 Drawing tab, 12-15 Title Block tab, 12-14 View tab, 12-17 Visibility tab, 12-16

G

Grid, GL-4 Guide Curve, GL-4

H

Mold Trim, Overview, 7-3

Half Angle, GL-2 Head, Sub-insert, 8-5 Extrude Edges to Sheet, 8-5 Forming Method, 8-5

O Object, GL-5 Offset Surface, GL-5

I

Origin, Cone, GL-2

K Knot Points, GL-4

L Layer, GL-5 Layout, 4-5, GL-5 Circular, 4-9 Rectangular, 4-6 Reposition, 4-14 Listing Window, GL-5 Load Product, 2-2, 4-3 and Mold Csys, 4-4 Project Initialize Proj Name, 2-4 Proj Path, 2-3 Unit, 2-2 Loaded Part, GL-5

M Menu, GL-5 Model, GL-6


P

Inflection, GL-4

Parametric Design, GL-5 Part, GL-5, GL-6 Partially Loaded Part, GL-6 Parting, 5-2 Auto Process, 5-2 Cavity_Core, 5-68 Core & Cavity, 5-68 Check Geometry, 5-68 Check Overlapping, 5-68 Create Cavity, 5-68 Create Core, 5-68 Extract Regions, 5-65 Parting Lines, 5-3 Auto Search Parting Lines, 5-4 Edit Parting Lines, 5-6 Transition Objects, 5-7, 5-8, 5-9, 5-10 Auto Transition Objects, 5-9 Edit Transition Objects, 5-9 Traverse Loop, 5-5 Parting Surfaces, 5-30 Auto Cavity Core, 5-41 Choosing a type, 5-39, 12-11 Create Parting Surfaces, 5-31 Edit Parting Surfaces, 5-40 Sew Surfaces, 5-40 Transition Objects, 5-3 Parting Lines, 5-3 Auto Search Parting Lines, 5-4



IN-3


Index Edit Parting Lines, 5-6 Transition Objects, 5-7, 5-8, 5-9, 5-10 Auto Transition Objects, 5-9 Edit Transition Objects, 5-9 Traverse Loop, 5-5

Existing Surface, 3-18 Surface Patch, 3-15 Pocket Creation, 7-31 Overview, 7-3 Standard Part, 7-32 Target + Standard, 7-32 Target Body, 7-32

Parting Surfaces, 5-30 Auto Cavity Core, 5-41 Choosing a type, 5-39, 12-11 Create Parting Surfaces, 5-31 Distance, 5-30 Tolerance, 5-30 Edit Parting Surfaces, 5-40 Sew Surfaces, 5-40

Point Set, GL-6 Point Subfunction, GL-6 Product Design Advisor, 5-4 Profile Split, 3-40 Proj Name, 2-4

parting_extrude_distance, 5-30 Parts Used bracket, A-20 cap, 3-41 case2, A-4 case3, A-5 case6, 3-58, 5-81 connhsg, A-8 cup_1, 10-26 cup1, 5-16, 5-70, 10-26 cup2, 5-25 cup3, 3-12, 3-22, 3-31 desk_org, 10-6 dryer, 5-42 engine, A-19 family, 4-16 flange, A-2 game, A-22, A-23, A-24, A-25 housing, A-3 hub, 2-29, 4-24 iron, A-9 loctab, A-6 mouse, 2-19, 6-8, 7-45 mdp_mcl, 6-8 mdp_mcu, 2-11, 2-19, 6-8 outlet, 5-11, 5-74, 5-86, 8-9 phone, A-7 sawcover, A-10 sprayercap, A-11 tab, A-12 tray, 1-10, 1-18, 1-25, 1-39, 1-60, 1-81, 7-15, 7-33, 9-7, 9-19, 11-4, 11-17, 12-6, 12-19 wrench, A-21 Patch Block, 3-28 Create Box, 3-28 Patch Up Overview, 3-9 Sheet Patch Up Auto Patch, 3-19 Edge Patch, 3-16

IN-4


Project Initialize, 2-2 Proj Name, 2-4 Proj Path, 2-3 Unit, 2-2

R ReadĆOnly Part, GL-6 Real Time Dynamics, GL-6 Rectangle Layout, 4-6 Refresh, GL-6 Reposition, 4-14 Auto Center, 4-15 Remove, 4-15 Removing the only instance, 4-29, 12-9 Rotate, 4-14 Transform, 4-15 Right Hand Rule, GL-6 Rotation, GL-6 Runner, 9-14 Delete, 9-18 Design Steps, 9-14 Create Runner Channel, 9-18 Define Guide String, 9-15 Add / Remove Curves from String, 9-16 Curves through Points, 9-16 Sketch Pattern, 9-15 Projection onto parting faces, 9-17 Copy Method, 9-17 Curves, 9-17 Parting Faces, 9-17 Reposition, 9-18

S SCS, GL-7 Search Parting Lines Eject Direction, 5-4, 5-7, 5-8



Index Select Body, 5-4 Sew Surfaces, 5-40 Sheet, GL-6 Sheet Patch Up, 3-15, 3-56 Edge Patch, 3-16 Enlarge Surface, 3-56 Auto Patch, 3-19 Existing Surface, 3-18 Surface Patch, 3-15 Shrinkage, 2-16 Edit Scale, 2-16 Sketch, GL-6 Coordinate System, GL-7 Slider and Lifter, 7-40 Head Design, 7-42 Orientation of..., 7-44 Overview, 7-3 Sub Assembly Structure, 7-43 Solid Body, GL-7

SubĆassembly, GL-7 Sub-Inserts, 8-2 Envelope, 8-4 Definition Method, 8-4 Shape, 8-4 Working Part, 8-4 Foot, 8-7 Copy Sub-insert Component, 8-8 Foot List, 8-8 Sub-insert Part Name, 8-7 Head, 8-5 Extrude Edges to Sheet, 8-5 Forming Method, 8-5 Standard Parts as, 8-3 Subtract, 3-39 Surface, GL-7 Surface Patch, 3-15 Surface Split, 3-29 System, GL-7

Solid Parting, 3-38

T

Solid Patch Up, 3-10, 3-30 Solid Split, 3-39

Temporary Part, GL-7

Spline, GL-7

TfrĆISO, GL-4

Split, 3-39

TfrĆTri, GL-7

Split Method, 3-38 Profile Split, 3-40 Solid Parting, 3-38 Solid Split, 3-39 Split, 3-39 Subtract, 3-39 Surface Split, 3-29

Toolbar Icons Bill of Materials, Overview, 12-2 Cooling, 10-2 Create Mold Drawing, 12-14 Ejector Pin Postprocessing, 7-26 Overview, 7-3 Electrode, 11-2, 11-3, 11-10 Family Mold, 4-2 Gate, 9-3 Layout, 4-5 Load Product, 2-2, 4-3 Mold Base Management, 6-2 Mold Csys, 2-15 Mold Trim, Overview, 7-3 Parting, 5-2 Auto Process, 5-2 Cavity_Core, 5-68 Core & Cavity, 5-68 Extract Regions, 5-65 Parting Surfaces Auto Cavity Core, 5-41 Create Parting Surfaces, 5-31 Edit Parting Surfaces, 5-40 Sew Surfaces, 5-40 Pocket Creation, 7-31 Overview, 7-3 Runner, 9-14 Shrinkage, 2-16

Standard Part Management, 7-5 Add/Modify, 7-8 Catalog, 7-5 Catalog Tab, 7-5 Classification, 7-6 Dimension Tab, 7-9 Edit / Database, 7-12 Flip Direction, 7-6 Operation Tab, 7-12 Overview, 7-3 Parent, 7-7 Position, 7-7 Remove Component, 7-12 Reposition, 7-12 Standard Part Name, 7-6 True / False Bodies, 7-7 Stored Layout, GL-7 Stored View, GL-7 String, GL-7




IN-5


Index Slider and Lifter, 7-40 Slides and Lifters, Overview, 7-3 Standard Part Management, 7-5 Overview, 7-3 Sub-Inserts, 8-2 Tools, 3-2, 3-15, 3-28, 3-38, 3-56 Patch Up, Overview, 3-9 Work Piece, 2-23 Tools, 3-2, 3-15, 3-28, 3-38, 3-56 Allow Non-Associative, 3-10 Create Patch Block, 3-28 Sheet Patch Up, 3-15, 3-56 Enlarge Surface, 3-56 Solid Patch Up, 3-10, 3-30 Planar Patch, 3-10 Solid Patch, 3-30 Split Method, 3-38 Profile Split, 3-40 Solid Parting, 3-38 Solid Split, 3-39 Split, 3-39 Subtract, 3-39 Surface Split, 3-29 Tolerance, 3-9 Top-Down Modeling, GL-7 Transition Objects, 5-7, 5-8, 5-9, 5-10 Auto Transition Objects, 5-9 Edit Transition Objects, 5-9

UM_TRANSIT_POINTS, 5-49 Unigraphics, GL-7 Unit, 2-2 Units, GL-7 Upgrade, Component, GL-7

V Version, GL-8 View, GL-8 Isometric, GL-4 Trimetric, GL-7 Work, GL-8

W WCS, GL-8 Work Layer, GL-8 Work Part, GL-8 Work Piece, 2-23

X

Traverse Loop, 5-5 Trim, GL-7

XCĆAxis, GL-8

True / False Bodies, 7-7

Y

U

YCĆAxis, GL-8

UM_EXTRACT_CURVES, 3-50 UM_GR, 9-14

Z

UM_PARTING_LINES, 3-51, 5-29, 5-49 UM_TRANSIT_CURVES, 5-49

IN-6


ZCĆAxis, GL-8



Reference Chart Tear Outs These tear out reference charts are provided for your convenience.







Student Profile MoldWizard Design Process Name Employer U.S. citizen? Yes / No

Date

When is your planned departure time?________________am/pm Please answer the following questions as honestly as you can. We are concerned about providing training that meets your needs. If you have any additional comments please write them on the back of this form. 1. Job title: 2. Current responsibilities: 3. How long have you held these responsibilities? Years ______ Months ______ 4. How long have you been working with CAD/CAM/CAE systems? Years ______ 5. What other CAD/CAM/CAE systems are you familiar with? 6. Are you currently using Unigraphics? _______ Version _______ Hours per week? 7. Is anyone at your company currently using MoldWizard? YES / NO Hours per week? 8. Do your customer models originate in Unigraphics? YES / NO 9. Please describe how much and what kind of repair" work you have to do to use models you receive? (use back if necessary) 10. Please list other completed CAD/CAM/CAE courses and the provider including Unigraphics CBT and CAST:

Course

Provider

11. Please check the box that best describes your current skill level in the various Unigraphics disciplines listed below. none

novice

intermediate

advanced

future use

Wireframe Modeling Solid Modeling Parametric Modeling Drafting Assemblies Manufacturing



Additional Comments




MoldWizard Design Process – Course Agenda Day 1

Monday Morning Introduction Lesson 1.

Overview of MoldWizard

Afternoon

Day 2

Lesson 2. Initializing a Project Workbook Section 1 Initialize the Wagon Projects Lesson 3. Parting Preparation Workbook Section 2 Patching the Wagon Projects

Tuesday Morning Lesson 3. Parting Preparation (concluded) Lesson 4. Family Molds and Layout Workbook Section 3 Layout for the Wagon Projects

Afternoon Lesson 5. Core and Cavity Definition Workbook Section 4 Identify Core and Cavity in Wagon Projects

Day 3

Wednesday Morning

Lesson 5. Core and Cavity Definition (concluded) Workbook Section 5 Identify Core and Cavity in Wagon Projects (concluded) Lesson 6. Mold Base Workbook Section 6 Add Mold Bases and continue work on Wagon Projects

Afternoon Lesson 7. Standard Parts Workbook Section 7 Add Ejectors, Post Process, , Add Slides And Lifters

Day 4 Morning Lesson 8. Sub Inserts Workbook Section 8 Create a Sub Insert and Prepare a Slide

Afternoon Lesson 9. Gates and Runners Workbook Section 9 Add Gates and Runners in Wagon Projects

Day 5 Morning

Lesson 10. Cooling Workbook Section 10 Add Cooling Lines in Wagon Projects Lesson 11. Electrodes Workbook Section 11 Add Electrodes in Wagon Projects

Afternoon Lesson 12. Bill of Materials and Mold Drawings Workbook Section 12 Add Bill of Materials and Drawings in Wagon Projects







The MoldWizard Design Process The MoldWizard Design Process requires a Unigraphics 3D solid part model that is moldable as designed:

We recommend that solid models be modeled in Unigraphics.

If the solid model is not moldable as designed, we recommend that you correct it using standard Unigraphics modeling techniques. Correct models will take full advantage of MoldWizard automation.

The first steps in the diagram below represent the High Level Preparation process of creating and evaluating a part model for moldability. Once the part model is moldable, use MoldWizard Design Functions to determine how the part will be molded. High Level Preparation

Intialize: project name location units

Create suitable solid model

Define Parting Sheets

Define: orientation shrinkage work piece

Visually Inspect: draft parting

Acceptable?

MoldWizard Design Functions

No

MoldWizard Design Advisor

Add the Moldbase

Add: ejectors slides, lifters sub inserts

Yes

Plan:

side actions layout sub inserts ejection gating cooling electrodes

No

Acceptable?

Yes Patch Holes


Complete the design with: gates runners cooling electrodes pockets Bill of Mat'ls Drafting


The MoldWizard Design Process follows common moldmaking practices. The icons found on the toolbar represent the many steps encountered in mold design. Moreover, the icons and process steps they represent are organized in a left to right order that closely matches the process flow chart shown on the preceding page.

Shrink

Load Product

Tools Parting

Work Piece Family Mold

Layout

Standard Parts

Electrodes Ejector Pins

A Plate

Mold Trim

Runners

Mold Base

Mold CSYS

Fixed Half

Cooling

Gate

Sliders and Lifters

B Plate

Bill of Material

Pockets

Sub Inserts

Moveable Half

Ejector Plate Return Pins

Mold Drawings

Ejector Plate

s

Retaining Ring & Sprue Bushing Mounting Plate


Cavity Insert (Inside A Plate)

Ejector Pins


Core Insert

Mounting Plate


Removing the only instance of a product The layout function does not provide the ability to remove the only instance of a product from a MoldWizard assembly. The following step by step procedure is provided for anyone who is not fully comfortable with Unigraphics assemblies functionality. Procedure:

Make the layout part the work part.

Close all product related parts using either File Close Selected Parts, or the Assembly Navigator. Related parts consist of the prod" sub assembly with its shrink, parting, core, cavity, and if necessary, the original product part. Removed component parts still open in memory would reappear on disk after a Save All.

Remove the prod" component from your Layout sub assembly

Select the component in the Assembly Navigator

Choose Edit Delete

A warning will appear that component(s) will be removed, but the parts will not be deleted.

Remove the prod" part and its child parts from your project directory manually using your operating system. Removed component parts that are still present in your project directory can cause future problems if you decide to add the product again. When you first closed the parts from memory, you prevented the possibility of them reappearing in your directory due to a Save All.

Save All. This saves the assembly structure as modified. If you fail to save after the above steps, you will get error messages about missing component parts when you next open your assembly. If you had failed to close the unwanted parts from memory, they would reappear in your project directory at this point.







Choosing a Parting Surface Type MoldWizard highlights parting segment

ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÇÇÇÇÇÇ ÉÉÉÉÉÉÉ ÇÇÇÇÇÇ ÉÉÉÉÉÉÉ ÇÇÇÇÇÇ ÏÏÏÏÏÏÏÏÏ ÉÉÉÉÉÉÉ ÏÏÏÏÏÏÏÏÏ ÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÇÇÇÇÇÇ ÇÇÇÇÇÇ ÇÇÇÇÇÇ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÇÇÇÇÇÇÇ ÉÉÉÉÉÉ ÇÇÇÇÇÇÇ ÉÉÉÉÉÉ ÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏ ÇÇÇÇÇÇ ÉÉÉÉÉÉÉ ÇÇÇÇÇÇ ÉÉÉÉÉÉÉ Planar Face?

No

Yes


No

Angle between directions < 180°?

No

BOUNDED PLANE

ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ Yes

EXTRUDE

ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ Yes

SWEPT

Same Surface?

No

Yes


ENLARGED SURFACE

No

Yes

SWEPT

EXTRUDE







Hot Key Chart Hot Key CtrlĆA CtrlĆB CtrlĆC CtrlĆD CtrlĆE

Function Assembly Navigator Edit, Blank Copy Delete Tools, Expression

Hot Key CtrlĆN CtrlĆO CtrlĆP CtrlĆQ CtrlĆR

CtrlĆF CtrlĆG CtrlĆH CtrlĆI CtrlĆJ CtrlĆK CtrlĆL CtrlĆM

Fit View Grip Execute

CtrlĆS CtrlĆT CtrlĆU CtrlĆV CtrlĆW CtrlĆX CtrlĆY CtrlĆZ

CtrlĆShiftĆA CtrlĆShiftĆB

CtrlĆShiftĆG CtrlĆShiftĆH

File, Save As CtrlĆShiftĆN Edit, Blank, Reverse CtrlĆShiftĆO Blank All View, Curvature Graph CtrlĆShiftĆP CtrlĆShiftĆQ CtrlĆShiftĆR Format, Layout, Fit All CtrlĆShiftĆS Views Debug Grip CtrlĆShiftĆT High Quality Image CtrlĆShiftĆU

CtrlĆShiftĆI CtrlĆShiftĆJ CtrlĆShiftĆK

CtrlĆShiftĆV CtrlĆShiftĆW CtrlĆShiftĆX

CtrlĆShiftĆC CtrlĆShiftĆD CtrlĆShiftĆE CtrlĆShiftĆF

Information, Object Edit, Object Display Format, Layer Settings Application, Modeling

Preferences, Object Edit, Blank, Unblank Selected

CtrlĆShiftĆL CtrlĆShiftĆM Model Navigator


CtrlĆShiftĆY CtrlĆShiftĆZ

Function File, New File, Open File, Plot View, Operation, RoĆ tate (full menu) File, Save Edit, Transform Execute Function Paste Application, Gateway Cut Edit, Undo Format, Layout, New Format, Layout, Open Tools, Macro, Playback Quick Shaded Image Tools, Macro, Record

Preferences, Selection Edit, Blank, Unblank All Of Part Format, Visible In View

View, Operation, Zoom (full menu)


Hot Key AltĆTab AltĆF4 F1

Function Toggles Application Closes Active Window Help on Context

Hot Key CtrlĆAltĆW CtrlĆAltĆ CtrlĆAltĆM

F3 F4

View Current Diaformation Window

CtrlĆAltĆO CtrlĆAltĆX

F5 F6 F7

Refresh Quick Zoom Quick Rotate

CtrlĆAltĆC CtrlĆAltĆB CtrlĆAltĆN



Function Application Assemblies Application ManufacĆ turing Operation Navigator Tools, Lathe CrossSection Tools, CLSF Tools, Boundary Tools, Unisim


MoldWizard Design Process Evaluation Name (Optional)

Date

Instructor

Location

UG Version ??

Please give your honest opinion about the training you have received during this class. Provide additional comments on the reverse side of this evaluation form. Please check the box if you would like your comments, regarding the training you just received, featured in our training publications. We will you if more information is needed. Hotel Accommodations (if applicable) Hotel name What was your overall impression of this hotel?

Poor 2

3

4

5

6

7

Facilities - How would you rate the training facilities?

Poor 2

3

4

5

6

7

Instruction - How would you rate the instruction?

Poor 2

3

4

5

6

7

Was the instructor knowledgeable of the subject?

Poor 2

3

4

5

6

7

Comments

1. Were the course objectives clearly defined and were they met? Please explain: 2. Did the course meet your expectations? Please explain:

Yes

Yes

No

No

3. Was the courseware clear and easy to follow? Please explain: 4. Were any topics not covered that are necessary for Mold Design at your site? Please explain:

5. Were the student activities effective? Please explain:

Yes

No

6. Do you feel comfortable with your knowledge of Interpart Modeling and Assemblies? Please explain:

Yes

over



No

7. Do you feel there was an appropriate balance of group discussions, lectures, and activities? Please explain: 8. Did you experiment with using Standard Parts as sub-inserts? Please explain:

Yes

No

9. Do you anticipate creating standard parts and customizing MoldWizard parts? Please explain the type(s) of parts that you expect to customize:

10. Did you experiment with Registration and Database spreadsheets? Yes Which MoldWizard menus are you most likely to extend or customize?

Yes

No

No

11. What Unigraphics training did you have prior to this class? (Please list classes)

12. Was your prior training sufficient to use MoldWizard in your work? Please explain:

Yes

No

13. How many weeks / months / years Unigraphics experience did you have before this class? 14. Is your prior experience sufficient to be comfortable using Unigraphics at work? 15. In order to continually improve our courseware a post class survey is conducted; would you be willing to participate in this survey.

(If you check this box, please make sure that your name is on this sheet.)

Course - What was your overall impression?

Poor 2

3

4

5

6

7

Additional Comments




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More details 6z3438

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