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Release 2000i2T009-310-01

CopyrightFundamentals of Mold Design

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This Fundamentals of Mold Design Training Guide may not be copied, reproduced, disclosed,transferred, or reduced to any form, including electronic medium or machine-readable form, ortransmitted or publicly performed by any means, electronic or otherwise, unless Parametric TechnologyCorporation (PTC) consents in writing in advance.

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Pro/ENGINEER and Pro/MECHANICA are registered trademarks, and all product names in the PTCproduct family and the PTC logo are trademarks of Parametric Technology Corporation in the UnitedStates and other countries. All other companies and products referenced herein have trademarks orregistered trademarks of their respective holders.

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2000 Parametric Technology Corporation. Unpublished all rights reserved under the copyright lawsof the United States.

PRINTING HISTORYDocument No. Date Description

T009-310-01 08/15/00 Initial Printing of Fundamentals of Mold Design for Release 2000i2

Order Number DT-009-310-EN

Printed in U.S.A

Training AgendaFundamentals of Mold Design

Day 18:30-8:45 Introductions and Logistics

8:45-9:00 Mold Design Course Overview

9:00-10:00 Getting Started With Mold Design & Demo

10:00-10:15 Break

10:30-12:00 Exercise

12:00-1:00 Lunch

1:00-1:30 Exercise (continued)

1:30-2:00 Creating Mold Assembly Features

2:00-3:15 Exercise

3:15-3:45 Parting Surface Creation

3:45-5:00 Exercise

Day 28:30-9:00 Exercise (continued)

9:00-9:30 Silhouette Curves & Skirt Surfaces

9:30-10:30 Exercise

10:30-10:45 Break

10:45-11:15 Split t ing the Mold

11:15-12:00 Exercise

12:00-1:00 Lunch

1:00-1:30 Exercise (continued)

1:30-2:00 Creating Mold Volumes Directly

2:00-3:45 Exercise

3:45-4:00 Break

4:00-4:30 Feature List Management

4:30-5:00 Exercise

Day 38:30-9:00 Exercise (continued)

9:00-9:40 Mold Layout

9:40-9:50 Break

9:50-12:00 Exercise

12:00-1:00 Lunch

1:00-1:30 Design for Moldabili ty

1:30-2:30 Exercise

2:30-3:00 Regeneration Failures in the Mold

3:00-5:00 Exercise

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AcknowledgmentsThe Pro/ENGINEER curriculum is a joint development effort between the courseware developmentteams at PTC and RAND Worldwide.

Both companies strive to develop industry leading training material and in turn deliver it to you, thecustomer.

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Table of ContentsFundamentals of Mold Design

MOLD DESIGN OVERVIEW 1-1INTRODUCTION ..............................................................................................................1-2MOLD PROCESS ..............................................................................................................1-2MODULE SUMMARY......................................................................................................1-5

GETTING STARTED WITH THE MOLD DESIGN 2-1GETTING STARTED ........................................................................................................2-2

Design and Reference Models ........................................................................................... 2-2Workpiece.......................................................................................................................... 2-6

PRO/MOLDESIGN FILES ................................................................................................2-8File Types........................................................................................................................... 2-8Mold Model ....................................................................................................................... 2-8Mold Assembly.................................................................................................................. 2-9Saving Files........................................................................................................................ 2-9File Management ............................................................................................................... 2-9

SHRINKAGE .....................................................................................................................2-9Shrinkage Feature ............................................................................................................ 2-10Shrinkage Formulas ......................................................................................................... 2-11Shrinkage by Dimension.................................................................................................. 2-11Shrinkage by Scaling ....................................................................................................... 2-12Shrinkage Info.................................................................................................................. 2-13

LABORATORY PRACTICAL........................................................................................2-15EXERCISE 1: Reference Part Layout and Shrinkage...................................................... 2-15EXERCISE 2: Automatic Workpiece Creation................................................................ 2-19EXERCISE 3: Reference Part Layout.............................................................................. 2-23

MODULE SUMMARY....................................................................................................2-29

MOLD ASSEMBLY FEATURES 3-1ASSEMBLY FEATURES..................................................................................................3-2

The Waterline Feature........................................................................................................ 3-2The Runner Feature............................................................................................................ 3-2

Ejector Pin Clearance Holes ...............................................................................................3-3USER-DEFINED FEATURES .......................................................................................... 3-4

Creating a UDF ..................................................................................................................3-4Creating UDFs....................................................................................................................3-5Placing a UDF ....................................................................................................................3-7

LABORATORY PRACTICAL ....................................................................................... 3-11EXERCISE 1: Creating Runners and Waterlines .............................................................3-11EXERCISE 2: Creating UDFs..........................................................................................3-20EXERCISE 3: Placing UDFs ...........................................................................................3-23

MODULE SUMMARY ................................................................................................... 3-27

PARTING SURFACE CREATION 4-1SURFACE FEATURES..................................................................................................... 4-2

Creating Surface Features...................................................................................................4-3Merging Surface Patches....................................................................................................4-5Trimming Surface Patches .................................................................................................4-5Extending Surfaces.............................................................................................................4-7Modifying and Redefining Parting Surfaces ......................................................................4-8

LABORATORY PRACTICAL ......................................................................................... 4-9EXERCISE 1: Creating a Planar Parting Surface...............................................................4-9EXERCISE 2: Creating a Compound Parting Surface .....................................................4-12EXERCISE 3: Creating Parting Surfaces Using Extend ..................................................4-23

MODULE SUMMARY ................................................................................................... 4-31

SILHOUETTE CURVES AND SKIRT SURFACES 5-1SILHOUETTE CURVES................................................................................................... 5-2

Interpretation of Slides .......................................................................................................5-3Gap Closure........................................................................................................................5-3Loop Selection....................................................................................................................5-4

SKIRT PARTING SURFACE ........................................................................................... 5-4Extension Control...............................................................................................................5-5

LABORATORY PRACTICAL ......................................................................................... 5-7EXERCISE 1: Silhouette Curve and Skirt Surface ............................................................5-7EXERCISE 2: Skirt Surface Extension Control ...............................................................5-11

MODULE SUMMARY ................................................................................................... 5-19

SPLITTING THE MOLD 6-1SPLITTING THE MOLD .................................................................................................. 6-2

One Volume Split ...............................................................................................................6-2

Two Volume Split .............................................................................................................. 6-3Split Classification ............................................................................................................. 6-3

ADVANTAGES OF SPLITTING WITH A PARTING SURFACE .................................6-4EXTRACTING MOLD VOLUMES..................................................................................6-4MOLDING..........................................................................................................................6-6MOLD OPENING ..............................................................................................................6-6LABORATORY PRACTICAL..........................................................................................6-9

EXERCISE 1: Splitting the Rod Mold............................................................................... 6-9EXERCISE 2: Splitting the Surface Mold ....................................................................... 6-14EXERCISE 3: Splitting the Pen Cap Mold...................................................................... 6-18EXERCISE 4: Classifying Mold Volumes ...................................................................... 6-20

MODULE SUMMARY....................................................................................................6-21

MOLD VOLUMES CREATED DIRECTLY 7-1CREATING VOLUMES....................................................................................................7-2

Gather Feature.................................................................................................................... 7-2Sketching Volumes ............................................................................................................ 7-5Reference Part Cutout ........................................................................................................ 7-6Offset ................................................................................................................................. 7-6Draft and Rounds ............................................................................................................... 7-7Attach................................................................................................................................. 7-8

MODIFYING MOLD VOLUMES ....................................................................................7-8LABORATORY PRACTICAL..........................................................................................7-9

EXERCISE 1: Creating Mold Volumes Directly............................................................... 7-9EXERCISE 2: Creating a Remote Mold .......................................................................... 7-14EXERCISE 3: Creating Mold Volumes Directly............................................................. 7-24

MODULE SUMMARY....................................................................................................7-31

FEATURE LIST MANAGEMENT 8-1MOLD FEATURE LIST ....................................................................................................8-2

Feature List Management and Local Groups ..................................................................... 8-5MOLD OPERATIONS TO WORK WITH THE MOLD ..................................................8-6MODEL REGENERATION ..............................................................................................8-7MOLD INFORMATION....................................................................................................8-8LABORATORY PRACTICAL..........................................................................................8-9

EXERCISE 1: Organizing Mold Features ......................................................................... 8-9EXERCISE 2: Modifying the Remote Mold.................................................................... 8-13

MODULE SUMMARY....................................................................................................8-17

MOLD LAYOUT 9-1MOLD LAYOUT............................................................................................................... 9-2

Cavity Population ...............................................................................................................9-2Mold Base Selector ............................................................................................................9-4Injection Molding Machine Selector ..................................................................................9-5Mold Catalog Items ............................................................................................................9-5Mold Feature Creation........................................................................................................9-7Layout Information Display ...............................................................................................9-7

LABORATORY PRACTICAL ......................................................................................... 9-9EXERCISE 1: Assembling a Moldbase to the Latch Mold................................................9-9EXERCISE 2: Ejector Pin Catalog...................................................................................9-17

MODULE SUMMARY ................................................................................................... 9-21

DESIGN FOR MOLDABILITY 10-1DRAFT............................................................................................................................. 10-2

Terminology .....................................................................................................................10-2Types of Drafts .................................................................................................................10-3Tips and Techniques for Draft..........................................................................................10-7

ROUNDS ......................................................................................................................... 10-7Round Types.....................................................................................................................10-7Tips on Performance.......................................................................................................10-13Troubleshooting Rounds ................................................................................................10-13

MOLD CHECK ............................................................................................................. 10-13Draft Check ....................................................................................................................10-13Thickness Check.............................................................................................................10-143-D Waterline Clearance Check .....................................................................................10-16

LABORATORY PRACTICAL ..................................................................................... 10-17EXERCISE 1: Creating Draft.........................................................................................10-17EXERCISE 2: Draft Checks...........................................................................................10-22EXERCISE 3: Thickness Check.....................................................................................10-25

MODULE SUMMARY ................................................................................................. 10-29

REGENERATION FAILURES IN THE MOLD 11-1RESOLVE ENVIRONMENT OVERVIEW ................................................................... 11-2

Causes of Regeneration Failures ......................................................................................11-2The Resolve Environment ................................................................................................11-3

ADDRESSING THE PROBLEM.................................................................................... 11-3The Backup Model ...........................................................................................................11-3Diagnosing the Cause of Failure ......................................................................................11-4Fixing the Model ..............................................................................................................11-5

MOLD ACCURACY .......................................................................................................11-6Relative Accuracy............................................................................................................ 11-6Absolute Accuracy........................................................................................................... 11-7

LABORATORY PRACTICAL........................................................................................11-9EXERCISE 1: Fixing Regeneration Failures ................................................................... 11-9

MODULE SUMMARY..................................................................................................11-19

USING PTC.HELP A-1PTC HELP OVERVIEW...................................................................................................A-2PTC HELP FEATURES....................................................................................................A-2USING THE PRO/ENGINEER HELP SYSTEM.............................................................A-2

Getting Help While Performing a Task............................................................................. A-2GETTING HELP THROUGH THE PTC HELP SIDEBAR.............................................A-3PTC HELP MODULE LIST..............................................................................................A-4

PTC GLOBAL SERVICES: TECHNICAL SUPPORT B-1FINDING THE TECHNICAL SUPPORT PAGE.............................................................B-2OPENING A TECHNICAL SUPPORT CALL ................................................................B-2

Opening a call via email: .................................................................................................. B-2Opening a Call via Telephone:.......................................................................................... B-3Opening calls on the PTC Web Site:................................................................................. B-3Sending Data to Technical Support................................................................................... B-3

CALL / SPR FLOW CHART AND PRIORITIES............................................................B-4REGISTERING FOR ON-LINE SUPPORT.....................................................................B-5ONLINE SERVICES.........................................................................................................B-6FINDING SOLUTIONS IN THE KNOWLEDGE BASE ................................................B-6GETTING UP-TO-DATE INFORMATION ....................................................................B-8CONTACT INFORMATION............................................................................................B-8

Internet .............................................................................................................................. B-8Telephone.......................................................................................................................... B-9

ELECTRONIC SERVICES.............................................................................................B-13

1

Module

Mold Design OverviewMold design enables you to create a mold model based on thegeometry of Pro/ENGINEER models. This module introduces thegeneral process that you perform during a typical Pro/MOLDESIGNsession.

Objectives

After completing this module, you will be able to:

Understand the process of creating a mold model

2 Fundamenta ls of Mo ld Des ign

NOTES

INTRODUCTIONPro/MOLDESIGN is an optional module in Pro/ENGINEER that providesyou with tools to simulate the mold design process within Pro/ENGINEER.You can design a mold around an existing solid Pro/ENGINEER part,eliminating the need to re-create the original geometry in the mold. Also,the parametric nature of the system enables you to quickly update themold after the design model is changed.

MOLD PROCESSThe Pro/MOLDESIGN process consists of the following steps. These stepswill be discussed in detail in this training course.

1. Create a mold model by assembling or creating reference modelsand workpieces. The reference model represents the model that isbeing molded and the workpiece represents the A and B plates thatare used in the mold model.

2. Create shrinkage on your mold model. Applying shrinkage valuesto the reference model increases the models dimensions inproportion to the amount of shrinkage that occurs during themolding process.

3. Add gates, runners, and waterlines as mold features. They will beconsidered when creating the molded part, as well as forinterference checking during the mold opening process.

4. Define the parting surfaces to split the workpiece into separatemold volumes.

5. Split the mold volumes based on the parting surfaces. Thisproduces two mold volumes (core and cavity). A mold volume is athree-dimensional, enclosed surface quilt with no mass.

6. Extract the mold volumes to produce mold components. Onceextracted, the mold components are fully functionalPro/ENGINEER parts, which you can bring up in Part mode, use inDrawings, or machine with Pro/NC.

7. Create the molding that represents the filled mold cavity. Thesystem creates the molding automatically by determining thevolume remaining in the workpiece after subtracting the extracts.

Mold Des ign Overv iew Page 1-3

NOTES

8. Define steps for mold opening. Check interference with static partsfor each step. Modify mold components if necessary.

9. Assemble mold base components, if needed. The mold basecomponents are the standard moldbase library parts that areobtained from suppliers such as Hasco and DME.

Mold Des ign Overv iew Page 1-5

NOTES

MODULE SUMMARYIn this module, you learned that:

Creating a mold model involves following a series of steps fromcreating the mold model all the way through to creating the moldcomponents and defining the opening.

During the molding process, changes to the design model may occur.When these changes are made to the design model, they will propagatethroughout all aspects of the design because the model is parametricand changes are reflected throughout all the intermediate process steps.

1

Module

Getting Started with the Mold DesignThis module introduces you to the various components used in aPro/ENGINEER mold model. As mold is a manufacturing model,there are several new types of components that are introduced. Sincethese components are critical to the mold design, it is important tounderstand the purpose of each type of component and theinterrelations before discussing mold creation.

Objectives


Create a new mold model by assembling the reference model andworkpiece

Recognize the different files that are created in Mold mode

Apply shrinkage to the mold model


NOTES

GETTING STARTEDTo begin a new Pro/MOLDESIGN session, click Manufacturing > Moldin the NEW dialog box, as shown in Figure 1. You have the option ofusing a default template for the mold model. This consists of defaultdatum planes and a coordinate system, saved views, and predefined layers.

Figure 1: NEW Dialog Box

Design and Reference ModelsThe design part geometry is a source for the mold reference part geometry.The relationship between the design part and reference part depends on themethod used to create the reference part.

When assembling a reference part, you can copy (merge by reference)design part geometry into the reference part. In this case, you can applyshrinkage to the reference part and create drafts, rounds, and otherfeatures; these changes will not affect the design model. However, anychanges in the design model are automatically reflected in the referencepart.

Gett ing Sta rted w i th the Mo ld Design Page 2-3

NOTES

As an alternative, you can designate a design part to be a mold referencepart. In this case, they will be the same models.

In both cases, using the geometry of a reference model while working inPro/MOLDESIGN sets up a parametric relationship between the designmodel and the mold components. Because of this relationship, when thedesign model is changed, any associated mold components are updated toreflect the change.

When creating multi-cavity molds, you can either pattern the referencemodel using the reference part layout functionality or assemble severalreference models that are all created from the same original design model.If you use the second approach you must be aware that if a feature isadded to one of the reference models, it will only appear on that onereference model. However, if changes to the original design model aremade, those changes will appear in all of the reference models.

Figure 2: Reference Models in a Multi-Cavity Mold

Mold Model

Design Model

Reference Model


NOTES

The following steps are used to create a reference part layout:

1. Click Mold Model > RefPart Layout > Create. The LAYOUTdialog box appears as shown in Figure 3.

Figure 3: LAYOUT Dialog Box

2. Click and select the design part from the OPEN dialog box.The CREATE REFERENCE MODEL dialog box opens, as shown inFigure 4. Click Merge By Ref or Same Model to use the designpart as the reference part. Click Ok.


NOTES

Figure 4: CREATE REFERENCE MODEL Dialog Box

3. Click to designate the reference model origin and orientation.The GET CSYS TYPE menu appears. A second Pro/ENGINEERwindow opens with the reference model in it.

4. Click Dynamic or Standard. If you choose Dynamic, the REFMODEL ORIENTATION dialog box opens, as shown in Figure 5,and enables you to orient the reference part. If you click Standard,select the coordinate system in the second Pro/ENGINEER window.Click OK when complete.

Figure 5: Dynamic Reference Model Orientation

5. To designate the layout origin, click in the LAYOUT dialogbox and select a coordinate system.

6. Select the layout configuration (Single, Rectangular, Circular, orVariable) and the orientation, if applicable.


NOTES

7. Depending on the layout configuration, you can then specifyconfiguration parameters (for example, the number of cavities andthe increments in the X and Y directions for a rectangularconfiguration).

WorkpieceThe workpiece represents the overall volume of the mold components thatdirectly participate in shaping the molten material (for example, the topand bottom inserts together). The workpiece can be an assembly of A & Bplates with inserts or simply an insert that is split into multiplecomponents. The workpiece can have standard overall dimensions to fit inthe standard base, or it can be custom-made to accommodate the geometryof the design model.

Figure 6: Workpiece

Automatic workpiece creation functionality gives you the ability to createa workpiece based on the reference model's size and position. Using theAUTOMATIC WORKPIECE dialog box, as shown in Figure 7, you can dothe following:

Orient the workpiece in relation to the mold base parting plane andpull direction

Create a custom size workpiece or select from standard sizes

Workpiece


NOTES

Save offsets used during the automatic workpiece creation to a file forfuture use

Figure 7: AUTOMATIC WORKPIECE Dialog Box

If the workpiece is a pre-existing part, you can assemble it in the moldassembly, or you can create the workpiece directly in the mold assembly.If you choose to create a workpiece, you have the options of Automaticand Manual.


NOTES

For manual workpiece creation, the COMPONENT CREATE dialog boxappears, as shown in Figure 8. The workpiece is then created using thesame process as if creating a component in an assembly.

Figure 8: COMPONENT CREATE Dialog Box

PRO/MOLDESIGN FILES

File TypesWhen working in Pro/MOLDESIGN, several different files will becreated. The following list shows these files:

Mold model MOLDNAME.MFG

Mold assembly MOLDNAME.ASM

Workpiece FILENAME.PRT

Reference part MOLDNAME_REF.PRT (default name)

Design model FILENAME.PRT

Mold ModelThe mold model is the top-level manufacturing model. This model isretrieved into Mold mode and contains all of the information necessary toregenerate the entire mold. The mold model contains the assembly of allof the reference parts, workpieces, and mold process information.


NOTES

Note: Whenever you assemble a new model into the mold, you willneed to classify it as a reference model, workpiece, mold basecomp, or general assembly. If general assembly is used, youwill need to classify all of the parts as one of the other three.

Mold AssemblyThe mold assembly is the top-level assembly in the mold model. Itcontains all reference models, workpieces, and mold base components aswell as all assembly level mold features. The mold assembly is a trueassembly file and is created automatically when the mold manufacturingmodel is created. The mold assembly can be retrieved in Assembly modeas long as the mold model is first in session.

Saving FilesWhen a mold model is stored, the new versions of the .mfg and .asmfiles are written to disk whether or not changes were made to the moldmodel. All other components are only stored if they have been changed.

File ManagementLike an assembly, it is important to keep all of the files within the mold inthe same directory as the mold file itself. Also, it is important to keep allcommon files in a library somewhere (usually write-protected), to keepthem from being inadvertently changed.

SHRINKAGEShrinkage is the contraction of the molding as it solidifies and cools.Applying shrinkage values to the reference model increases thedimensions of the reference model in proportion to the amount ofshrinkage that occurs during the molding process.

Before starting the molding process, you should set up for shrinkage.There are two methods of applying shrinkage, by dimension and byscaling.


NOTES

When you click Shrinkage in the MOLD menu, the SHRINKAGE menuappears with the following commands:

FormulaChoose a formula to define the shrinkage factor. Thedefault formula is that in which shrinkage is based on the originalgeometry of the part.

By DimensionSet up one coefficient for all model dimensions andspecify shrink coefficients for individual dimensions. The systemapplies this shrinkage to the design model and, therefore, to thereference part.

By ScalingShrink the part geometry by scaling with respect to acoordinate system. You can specify different shrink factors for eachcoordinate. This shrinkage only affects the reference model when setin Mold or Cast modes.

Shrink InfoDisplay the Information window, with shrinkageinformation for the current model.

Shrinkage FeatureWhen working with a shrinkage feature in a part, remember the followingpoints:

Entering a negative shrink reduces the dimension value; a positiveshrink increases the dimensional value.

When a part has shrinkage information associated with it, the nominaldimensions are displayed in magenta and the shrink value is displayedin parentheses, expressed as a percentage (by default), as shown inFigure 9. The shrink value can only be modified using theSHRINKAGE menu.

In order to work with shrinkage, all the Dim Bounds must be cleared.

When you apply suppressed shrinkage in Part mode, the dimensions inthe mold return to their nominal values and appear yellow.


NOTES

Figure 9: Part with Shrinkage Applied

Shrinkage FormulasThere are two formulas for calculating the shrinkage. The system promptsyou for the S value.

1+S The shrinkage factor is based on the models original geometry,and is the default choice.

1/(1-S) The shrinkage is based on the models resulting geometry.

Shrinkage by DimensionWhen applying shrinkage by dimension in Mold mode, Pro/ENGINEERplaces a shrinkage feature in the design model. You will be able to selectthe formula you want to use for calculating the shrink and the dimensionsyou want to apply the shrink to.

When specifying shrinkage by dimension, keep the following in mind:

Shrink values are not cumulative.

Shrinkage By Dimension does not shrink external references orimported geometry.


NOTES

When shrink is applied to a specific reference model in a multi-cavitymold, all reference models based on the same design model will havethe same shrink applied to them. In family molds, the shrink will onlyapply to reference models of a specific design model; the shrink doesnot affect reference models based on different design models.

Shrinkage By Dimension only affects those features created orreordered before the shrinkage feature.

Updating the Design Model

When shrink is applied By Dimension, a feature is added to the designmodel. The design model dimensions will reflect the altered values. Touse the design model without the shrink, the shrinkage feature can besuppressed without affecting the reference part geometry in the mold. Todo this from mold model, you update the design model either with shrinkor without shrink.

Shrinkage by ScalingShrinkage by Scaling creates a new assembly feature called shrinkagewhen applied in Pro/MOLDESIGN. Because it creates a feature inPro/MOLDESIGN, it will not affect the design model geometry. If there aremultiple reference models within a mold model, the system will promptthe user to select which models should be shrunk. To create the shrinkage,select a coordinate system feature and specify shrink values in the X, Y,and Z directions. The reference model geometry will then be scaled aboutthe selected coordinate system. All assembly offset values used in locatingthe reference models in the mold will also be shrunk.

Shrinkage by scaling is primarily used for anisotropic shrink as well as formodels that contain imported geometry because this geometry will beshrunk with a Shrinkage by Scaling feature.

Note: If Shrinkage By Scaling is applied to the design model in Partmode, then the shrinkage feature belongs to the design model,not to the references parts. Shrinkage will be accuratelyreflected by the reference part geometry, but it can not beupdated in Pro/MOLDESIGN.


NOTES

Shrinkage InfoClicking Shrink Info in the SHRINKAGE menu brings up an informationwindow with the following information:

The name of the design model

The status of the design model (that is, whether it is shrunk or notshrunk)

The name of the coordinate system for Shrinkage By Scaling

All shrinkage values set for the model


NOTES

LABORATORY PRACTICALGoal

The goal of these exercises is to learn how to create a mold model byassembling the reference model and the workpiece using varioustechniques. You will also learn to apply shrinkage to your models.

Method

In the first exercise, you will create a four-cavity mold for a rod part(Figure 10). You will assemble the reference parts using the LAYOUTdialog box. You will assemble the workpiece and apply shrinkage beforecontinuing with the molding process.

In the second exercise, you will create a single cavity mold and you willcreate a custom workpiece from within Mold mode (Figure 13). You willcomplete the exercise by adding shrinkage to the model.

In the third exercise, you will further investigate the options in thereference part layout to create multiple cavities in the mold.

EXERCISE 1: Reference Part Layout and Shrinkage

Figure 10: Four-Cavity Rod Mold

Task 1. Create a new mold model for ROD.PRT that consists of a 2 x 2reference part layout and a workpiece.

1. Click File > New.

2. Click Manufacturing as the type of model and Mold as the sub-type. Make sure that the Use default template option is selected.


NOTES

3. Name the mold [rod] and click OK.

4. Click Mold Model > RefPart Layout > Create. The LAYOUTdialog box appears.

5. Click in the dialog box and select ROD.PRT. Click Open. TheCREATE REFERENCE MODEL dialog box appears.

6. Click Ok to accept the defaults. A new reference part will becreated called ROD_REF.PRT.

7. In the LAYOUT dialog box, the system automatically selectsPRT_CSYS_DEF and MOLD_DEF_CSYS as the reference modelorigin and the layout origin, respectively. Click Preview. Thereference part needs to be rotated 90 about the X-axis to get it intothe preferred orientation.

8. Click in the Ref. Model Origin and Orient section and clickDynamic in the GET CSYS TYPE menu. The reference modelappears in a sub-window and the REF MODEL ORIENTATIONdialog box opens.

9. Accept the default of Rotate and X axis.

10. Type [90] in the Value field and click OK.

11. Click Preview. The reference model has been rotated and a newcoordinate system, REF_ORIGIN, is created in the reference part.

12. Click Rectangular in the Layout section of the dialog box.

13. Click Constant in the Orientation section of the dialog box.

14. By Default, there should be two cavities in the X and Y directions.Type [240] for the X increment and [90] for the Y increment.

15. Click Preview. The reference model layout should appear asshown in Figure 11.

Figure 11: Reference Part Layout


NOTES

16. Click Ok > Done/Return > Done/Return. Notice that a pattern ofthe ROD_REF.PRT component has been added to the Model Tree.

Task 2. Blank the reference parts and assemble the workpiece into themold.

1. Click in the toolbar. The BLANK UNBLANK dialog boxappears.

2. Click to select all of the visible components (that is, the fourreference parts) and click Blank.

3. Click Close.

4. Click Mold Model > Assemble > Workpiece.

5. Select ROD_WP.PRT.

6. Assemble the workpiece by aligning the yellow sides of theFRONT and MOLD_FRONT datum planes, the yellow sides of theRIGHT and MOLD_RIGHT datum planes, and the yellow sides ofthe TOP and MAIN_PARTING_PLN datum planes.

7. Click OK in the COMPONENT PLACEMENT dialog box.

8. Click in the toolbar.

9. Click the Unblank tab and click to select all of the blankedcomponents (that is, the four reference parts) and click Unblank.

10. Click Close. The mold model should appear as shown in Figure12. You may need to set the model to Hidden display and removedatum features from the display.

Figure 12: Reference Parts and Workpiece


NOTES

Note: The workpiece appears in green to identify the workpiece anddistinguish it from the other components. If your workpiecedoes not appear green, repaint your screen. If it still does notappear green, you probably assembled it as a reference partand it will have to be deleted and re-assembled as a workpiece.

Task 3. Add 0.25% overall shrink to the reference parts with the ByDimension type of shrinkage, and add 0.45% shrink to the rod length and0.15% shrink to the rod diameter.

1. Click Shrinkage in the MOLD menu.

2. Pick one of the reference models.

3. Click By Dimension > Set/Reset > All Dims.

4. Type [.0025] as the overall shrinkage.

5. Click By Dim and pick the center of the rod to highlight the baseprotrusion of the model.

6. Pick the rod length dimension (200.00) and type [0.0045] as theshrink value.

7. Pick the diameter dimension (10.00) and type [0.0015] as theshrink value.

8. Click Done in the SHRINK SET menu. Notice in the MessageWindow that the reference model automatically gets regenerated.

Task 4. Update the design model to show the nominal dimensionvalues.

1. Click Update > No Shrink > Done from the SHRINK BY DIMmenu. Notice in the Message Window that the rod part has beenregenerated with one suppressed feature, the shrinkage feature.

2. Click Shrink Info. The defined shrinkage should be documentedhere. Click Close.

3. Click Done/Return from the SHRINKAGE menu.

4. Save the model and erase it from memory.


NOTES

EXERCISE 2: Automatic Workpiece Creation

Figure 13: Casing Mold

Task 1. Create a new mold and assemble the casing part as a referencemodel.

1. Create a new mold model called [casing] using the defaulttemplate.

2. Click Mold Model > Assemble > Ref Model.

3. Select CASING.PRT from the OPEN dialog box.

4. Assemble the reference part by aligning the yellow sides of theFRONT and MOLD_FRONT datum planes, the yellow sides of theRIGHT and MOLD_RIGHT datum planes, and the yellow sides ofthe TOP and MAIN_PARTING_PLN datum planes.

5. Accept the Merge By Ref option and [casing_ref] as the nameof the reference model. The reference part should appear in themold as shown in Figure 13.


NOTES

Figure 14: Casing Reference Model

Task 2. Create an automatic workpiece.

1. Click Create > Workpiece > Automatic in the MOLD MODELmenu. The AUTOMATIC WORKPIECE dialog box appears.

2. Select the MOLD_DEF_CSYS coordinate system from the casingassembly as the Mold Origin.

3. Select BLOCK_CHAMF from the Shape drop-down list.

4. Accept the default units of INCH.

5. In the Overall Dimensions section of the dialog box, enter thevalues shown in Figure 15 (the Offsets section updatesautomatically).

Figure 15: Overall Dimensions


NOTES

6. Click OK.

7. Accept [casing_wrk] as the workpiece name. The workpieceshould appear as shown in Figure 16.

Figure 16: Automatic Workpiece

Task 3. Modify the parameter controlling the chamfer dimension.

1. The 45xd chamfer on the workpiece is controlled by a parameter inthe part. Click Set Up > Parameters > Part and pick theworkpiece.

2. Click Modify > Chamfer.

3. Type [0.50] as the new value.

4. Click Regenerate > Automatic in the MOLD menu.

Task 4. Add an overall shrinkage of 0.004 to the reference model.

1. Click Shrinkage, By Dimension, Set/Reset from the MOLDmenu.

2. Click All Dims and type [0.004] as the shrink value.


NOTES

3. Click Done.

4. Click Update > No Shrink > Done to update the design model toits unshrunk state.



NOTES

EXERCISE 3: Reference Part Layout

Task 1. Create a new mold model and assemble the workpiece.

1. Create a new mold model called [multi-cavity] using thedefault template.

2. Assemble the workpiece called MULTI_CAVITY_WP.PRT usingthe Default option on the Constraint Type pull-down menu in theCOMPONENT PLACEMENT dialog box.

Notes: The Default assembly constraint aligns the default system-created coordinate system of the component to the defaultsystem-created coordinate system of the assembly.

Task 2. Assemble the reference part using the reference part layout tool.

1. Click Mold Model > RefPart Layout > Create.

2. Click in the dialog box and select GAME_PIECE.PRT. TheCREATE REFERENCE MODEL dialog box appears.

3. Click Ok to accept the defaults. A new reference part will becreated called MULTI_CAVITY_REF.PRT.

4. Click in the Ref. Model Origin and Orient section and clickDynamic from the GET CSYS TYPE menu. The reference modelappears in a sub-window and the REF MODEL ORIENTATIONdialog box opens.

5. Accept the default of Rotate and X axis.


7. Accept the default Layout Origin.

8. Click Preview. The model appears as shown in Figure 17.


NOTES

Figure 17: Single Reference Part

9. Click Rectangular > Constant in the Layout and Orientationsections of the dialog box.

10. Type [4] as the number of cavities and [2] as the increment inboth the X and Y directions.


Figure 18: 4 x 4 Rectangular Layout


NOTES

Task 3. Change the orientation of the layout so that half the game piecesare facing one side of the mold and the other half are facing the other side.

1. Click X-Symmetric in the Orientation section of the dialog box.


Figure 19: X-Symmetric Layout

Task 4. Change the orientation to circular.

1. Click Circular in the Layout section of the dialog box.

2. Type [9] for the number of cavities, [3.25] for the radius, and[40] for the angular increment.



NOTES

Figure 20: Circular Layout

Task 5. Change the orientation of the game pieces so that they arefacing outside the circular pattern.

1. Click in the Ref. Model Origin and Orient section and clickDynamic from the GET CSYS TYPE menu.

2. Accept the default of Rotate but click Z axis.


4. Click Radial in the Orientation section of the LAYOUT dialog box.



NOTES

Figure 21: Circular Radial Pattern



NOTES

MODULE SUMMARYIn this module, you learned that:

The reference model is assembled in the mold model using theLAYOUT dialog box. This enables you to define the reference model,its origin, and the layout origin for creating multiple layouts of thereference model.

The workpiece represents the A and B plates in the mold. It can be astandard base or it can be custom made to accommodate the geometry.

Shrinkage should be added to the model before starting the moldingprocess. Shrinkage can be applied by formula or by dimension.

1

Module

Mold Assembly FeaturesThis module discusses the various mold assembly features that canbe created in mold design and how these features are created. InMold mode, there are standard assembly features such as cuts, slots,and holes. There is also a special class of features availablespecifically for molds. Additionally, user-defined features (UDFs)are discussed. UDFs are very useful for designing runner systemsthat are very similar from one mold to the next.

Objectives


Create water line features

Create runner features

Create and place a User Defined Feature (UDF) in a mold model


NOTES

ASSEMBLY FEATURESIn Mold mode, assembly level features are used to create the mold runnersystem, waterline circuit, and ejector pin clearance holes. These can becreated using conventional holes, cuts, and slots. There are severalfeatures available in Mold mode, however, that can speed up this process.

The Waterline FeatureThe waterline feature enables you to quickly create a waterline circuit byspecifying the circuit diameter, sketching the circuit path, and specifyingthe end condition. The following four end conditions are available:

None - The hole terminates at the end of the circuit leg.

Blind - The hole continues a blind distance beyond the end of thecircuit leg. The hole received a drill point end.

Thru - The hole continues through to the surface of the model.

Thru w/ Cbore - The hole continues through to the surface of themodel and is counterbored.

Figure 1: Waterline Feature

The Runner FeatureThe runner feature enables you to quickly create standard runnergeometry. To create a runner feature, pick one of the standard runner crosssections, as shown in Figure 2, type the cross section size, and sketch therunner path. The runner is then created by sweeping the chosen crosssection along the sketched path. The feature also creates rounded ends onthe runner to match standard runner geometry.

Mold Assembly Featu res Page 3-3

NOTES

Figure 2: Runner Shapes

Ejector Pin Clearance HolesThe ejector pin clearance hole feature is a specialized hole featureavailable only in Mold mode. It is similar to a standard hole feature exceptthat when you specify the diameter of the hole, you specify a differentdiameter through each plate that the hole intersects. Also, the hole isautomatically counterbored with a diameter and depth that you specify.

The ejector pin clearance hole has the same placement option as a standardhole (linear, radial, coaxial, and on point). If the ejector pins are alreadyassembled into the mold, coaxial placement makes the hole placementvery quick. Also, if there are several datum points in the model where theholes should be placed, you can simultaneously place holes on each pointwithin the same hole feature.

Figure 3: Ejector Pin Clearance Hole


NOTES

USER-DEFINED FEATURESA user-defined feature (UDF) is a collection of features and theirrespective dimensions and references that are captured into a group andsaved as a file. Typically, UDF files are saved in a specific directory orUDF library that can be accessed anytime and be placed onto a model byspecifying new references and dimensions of the features included in theUDF. It is an effective way to place common features that are usedrepeatedly on multiple models.

UDFs are frequently used in Mold mode for runner systems, as these tendto be very similar from one mold to the next. When creating UDFs to beused in Mold mode, it is important to only use assembly level featuresbecause the runner system is created at the assembly level.

Creating a UDFAn example of a UDF is the screw boss geometry shown in Figure 4. Oncethis geometry is created, we can save it as a UDF and very quickly reuse iton other models.

Figure 4: Screw Boss Geometry

Note: UDFs can be created in Part mode or Assembly mode and canconsist of part or assembly level features. If you are creating aUDF to be placed in a mold model, you need to ensure that allof the features in the UDF are assembly level features.

Before creating a UDF, you must model the geometry that you want tosave. It is important to be aware of the parent-child relationships that you


NOTES

are creating. Try to minimize the number of references used to create thegeometry by reusing references. For example, use the same plane as thesketching plane of one feature and as an alignment reference of another.

Creating UDFsOnce you have defined the geometry that you wish to save, the followinggeneral steps are used in creating the UDF:

1. Specify an option for the dependency of the UDF to the originalmodel.

2. Store a reference model.

3. Provide a name for the UDF.

4. Select the features to be included in the UDF.

5. Provide prompts for the external references.

6. Define any variable dimensions or feature elements.

7. Establish family tables or use Pro/PROGRAM for the UDF.

Specifying Dependency Option

When creating a UDF you will have the following two options for how itis stored and its dependency to the original model:

Standalone All of the information needed to create the features willbe stored in the UDF file. Any changes to the original model will notaffect the UDF.

Subordinate The features within the UDF will get some of theirinformation from the current model. Any changes to the originalmodel will be reflected in the UDF.

Note: For a subordinate UDF, if the current model is not presentwhen the UDF is accessed later, the system cannot retrieve theUDF.


NOTES

Storing a Reference Model

When creating a standalone UDF, you will have the option to store areference model. The reference model is used as a visual aid in placing theUDF on a future model. The reference model will be a copy of the currentmodel with the name UDFNAME_GP.PRT (or .ASM). If you are creatinga subordinate UDF, the current model will be used as the reference model.

Naming the UDF

Assign a unique and descriptive name to a UDF that is independent of themodel in which it was created. The system gives the file a .GPH extension.

Selecting Features

The features that you select to be included in the UDF do not have to beparents and children of each other, although this is often the case. Featuresincluded in an assembly-level UDF must be assembly-level features.

Specifying Prompts for External References

After selecting the features, you will need to provide prompts for all of thereferences to features outside the UDF. The prompts appear in theMessage window during UDF placement and assist in placing the UDF.They should describe what the reference is used for.

If an external reference is used by more than one feature in the UDF, youhave the option to provide a single prompt for the reference or multipleprompts for each time the reference is used.

Figure 5: Prompts for UDF External References

Placement Plane

Side Plane

Front Plane


NOTES

Defining Variable Dimensions and Elements

When defining a UDF, you have the option to specify variable dimensionsand feature elements. Specifically, you can do the following:

Make some, or all, of the feature dimensions variable. You mustprovide a prompt for any dimension that you specify as variable. Forany dimensions that are not selected, the system automatically uses thesame values that were assigned to the dimensions when it was stored.

Make any element of any feature in the UDF variable. An example ofan element is the depth element of a hole feature. You can make thisdepth element variable, thus providing the ability to change the holefrom blind to thru all when the UDF is placed.

Using Family Tables and Pro/PROGRAM with UDFs

Using Pro/PROGRAM, you can define prompts for information and uselogic statements to customize the UDF based on this information. Forexample, in the screw boss UDF, you could prompt for the number of ribsneeded and then modify this number based on the response. With familytables, you can establish predefined variations on the UDF. If there areseveral standard sizes of screw bosses that are frequently used, you cancreate these as instances in the family table.

Placing a UDFThe following general steps are used in placing a UDF:

1. Select a dependency option for the new geometry.

2. Specify the units of the new geometry.

3. Specify the status on invariable dimensions in the UDF.

4. Select new references and values for variable dimensions whenprompted.

5. Define any optional elements.After completing these steps, the system will create a group within thenew model containing the features. The group will have the same name asthe UDF.


NOTES

Specifying the Dependency of the New Geometry

When placing a UDF, you can specify whether the new geometry will beindependent or driven by the UDF file.

Independent The new group is completely independent of the UDFfile.

UDF Driven The new group is associated with the UDF file. If theUDF file changes, you can update the group in the new model toreflect the changes.

Specifying the UDF Units

When placing the UDF, you have an option for the units of the UDF.These options enable you to place a UDF defined in one unit system on amodel using another unit. The options are:

Same Size The new geometry will have the same physical size asthe original geometry. As a result, the dimension values are scaled if adifferent unit system is being used (that is, 1 25.4mm).

Same Dims The new geometry will retain the same dimensionvalues. As a result, the geometry will be scaled if a different unitsystem is being used (that is, 1 1mm).

User Scale You will be able to specify your own custom scale forthe dimensional values.

Specifying the Status of Invariable Dimensions

When creating the UDF, you specifically identify which dimensions willbe variable. All other dimensions are considered invariable. When youplace the UDF, you have a choice of how invariable dimensions appear inthe model.

Normal The invariable dimensions will be treated as any otherdriving dimension. They will appear in the model and can be modified.

Read Only The dimension will appear in the model but cannot bemodified.

Blank The dimension will not appear in the model, and thus, cannotbe modified.

Specifying References and Variable Dimensions

So that the system can create the group in the new model, pick appropriatereferences that correspond to the prompts, as shown in Figure 6. You can


NOTES

retrieve a reference model in a sub-window in order to assist in this. Theoriginal references will highlight on the reference model, making it easierto make a selection on the new model.

Figure 6: References and Variable Dimensions for UDF Placement

You are prompted for values for any dimensions that were chosen to bevariable. It is important to note the positive direction for these dimensionswhen entering a value in order to place the UDF in the correct location.

Figure 7: Positive Dimension Direction for UDF Placement

PlacementPage

SidePlane

Front Plane

Type 1.00 to place theUDF on this side of thedatum plane


NOTES


The goal of these exercises is to learn how to create mold featuresincluding runners, waterlines, and user-defined features.

Method

In the first exercise, you will add runners and waterlines to the four-cavityrod mold created in the last exercise.

In the second exercise, you will create a UDF of the features that make upthe opening for a hot nozzle. You will create the UDF with two assemblyfeatures that make up the opening. You will also create a family tablewithin the UDF to create two common sizes.

In the final exercise, you will place the hot nozzle UDF on theUDF_CASING.MFG mold.

EXERCISE 1: Creating Runners and Waterlines

Figure 8: Runner and Waterline Systems

Task 1. Open MOLD_FEATURE_ROD.MFG and create a layer on theworkpiece to aid in simplifying the number of datum references seen.

1. Open MOLD_FEATURE_ROD.MFG.

2. Click View > Layers. The LAYERS dialog box appears.

3. Click Part in the Active Object drop-down menu. When promptedto select a part, pick the workpiece.


NOTES

4. Click to create a new layer and type the name [def_dtms].Click OK.

5. Pick the DEF_DTMS layer and click to add an item to thelayer.

6. Click Datum Plane and pick each workpiece default datum plane(not the Assembly Datum Planes).

7. Click Done Sel > Done/Return.

8. Pick the DEF_DTMS layer and click . Click to see thechanges.

9. Close the dialog box to finish.

Task 2. Build the sprue using a revolved cut.

1. Click Feature > Mold Assem > Solid.

2. Click Cut > Revolve > Solid > Done.

3. Click One Side > Done.

4. Pick the MOLD_FRONT datum plane as the sketching plane andaccept the default direction of feature creation. Orient theMAIN_PARTING_PLN datum plane to the Top of the screen.

5. Pick the MOLD_RIGHT datum plane, the MAIN_PARTING_PLNdatum plane, and the top edge of the workpiece as references.

6. Sketch a centerline on top of the MOLD_RIGHT datum plane as theaxis of revolution

7. Sketch the section as shown in Figure 9.


NOTES

Figure 9: Sketched for Sprue Revolved Cut

8. Remove the appropriate side of the material and revolve the cut360 degrees.

9. Click Auto Sel > Confirm > Done for the component intersection.

10. Click OK.

Task 3. Create a standard H shaped runner system using runner moldassembly features.

1. Click Mold on the FEAT OPER menu.

2. Select Runner as the type of feature to create.

3. Accept the default name of [runner_1].

4. Click Round for the runners shape and type a diameter of [6].

5. Pick the MAIN_PARTING_PLN datum plane as the sketching planeand accept the default direction of feature creation. Orient themodel using Bottom and the MOLD_FRONT datum plane.


NOTES

6. Pick the FRONT datum plane from one of the top reference modelsand the FRONT datum plane from one of the bottom referencemodels as references.

7. Sketch a straight line as shown in Figure 10.

Note: Runner geometry is shown temporarily in Centerline font inSketcher.

Figure 10: Sketch for Primary Runner

8. Exit from Sketcher and click Auto Sel > Confirm > Done.

9. Finish the runner by clicking OK in the dialog box.

Task 4. Create a secondary runner.

1. Click Mold > Runner and accept the default name.

2. Click Round for the runner shape and type [3.25] as thediameter.

3. Click Use Prev in the SETUP SK PLN menu to use the previoussketching and reference planes. Accept the direction for viewingthe sketching plane.


NOTES

4. Pick the MOLD_RIGHT datum plane and the FRONT datum planefrom one of the top model reference parts as references.

5. Sketch a centerline on top of the MOLD_RIGHT datum plan toassume symmetry. Sketch a single straight line as shown in Figure11.

Figure 11: Sketch for Secondary Runner



Task 5. Create the gates at both ends of the last runner segment using atrapezoidal shaped runner feature.

1. Click Mold > Runner and accept the default name.

2. Click Trapezoid for the shape and type a width of [1], a depth of[.5], a side angle of [20], and a corner radius of [.1].

3. Click Use Prev and accept the default direction for viewing thesketching plane.

4. Pick the FRONT datum plane from one of the top model referenceparts and the edges of the reference parts as shown in Figure 12 asreferences.


NOTES

5. Sketch the section shown in Figure 12 and align the endpoints ofthe sketched line to the edges of the reference parts.

Figure 12: Sketch for Gate Runner Feature



Task 6. Mirror the two runner features to the other side of the mold.

1. Click Feature Oper > Copy > Mirror > Dependent > Done.

2. Pick the last two runner features created.

3. Click Done.

4. Pick the MOLD_FRONT datum plane as the plane to mirror about.The runners should appear as shown in Figure 13.

Figure 13: Runner System

Pick these edges as references


NOTES

Task 7. Create a set of waterlines on one side of the mold using thewaterline feature.

1. Click Done in the FEATURE OPER menu and click Mold to accessmold features.

2. Click Water Line and accept the default name.

3. Type [2.5] as the waterline diameter.

4. Click Make Datum when prompted for the sketching plane.

5. Offset the plane in the downward direction from theMAIN_PARTING_PLN datum plane by a distance of [15]. ClickDone.

6. Use the MOLD_FRONT datum plane as the Bottom reference.

7. Pick the bottom and left-hand edges of the workpiece asreferences.

8. Sketch the three lines shown in Figure 14.

Figure 14: Sketch for Waterline in Rod Mold


10. Double click the End Condition element in the dialog box.


NOTES

11. Pick the two open endpoints of the waterline circuit (defined asThru w/Cbore in Figure 15) and click Done Sel.

12. Click Thru w/Cbore > Done/Return as the end type.

13. Type [5.0] as the counterbore diameter and depth for both ends.

14. Pick the endpoint facing the side of the workpiece (defined as Thruin Figure 15) and click Done Sel.

15. Click Thru > Done/Return.

16. Pick the three remaining ends (defined as Blind in Figure 15) andclick Done Sel.

17. Click Blind > Done/Return.

18. Type [10.0] as the blind extension for all three ends.

19. Click Done/Return > OK to create the feature. The waterlinecircuit should appear as shown in Figure 15.

Figure 15: Waterline End Conditions

Task 8. Mirror the waterline feature to the other side of the mold.

1. Click Feature Oper > Copy > Mirror > Dependent > Done.

2. Pick the waterline feature.

Thru

Thru w/Cbore

Blind


NOTES

3. Pick the MOLD_RIGHT datum plane to mirror about. The modelshould appear as shown in Figure 16.

Figure 16: Finished Waterlines

4. Save the mold and close the window.


NOTES

EXERCISE 2: Creating UDFs

Task 1. Open the assembly called UDF_BLOCK.ASM and notice the twoassembly level features that make up the nozzle opening.

1. Open UDF_BLOCK.ASM.

2. If features are not visible in the Model Tree, click View > ModelTree Setup > Item Display. Click Features > OK in the MODELTREE ITEMS dialog box.

3. Notice that the model is made up of a single component(UDF_BLOCK.PRT) and two assembly-level features that make upthe nozzle geometry (cut and hole).

4. Click Info > Parent/Child.

5. Pick the cut feature. The REFERENCES INFORMATION windowappears. The parents are identified as the FRONT and RIGHTdatum planes and the protrusion.

6. Click in the Current Feature section of the dialog box andpick the hole feature. Identify the parents for this feature.

7. Close the window.

Figure 17: References for Nozzle Features

Cut sketching plane

Hole axis

Hole depth plane

Cutalignmentreference

Cut referenceplane and holeplacement plane


NOTES

Task 2. Create a UDF containing these two features.

1. Click Feature > UDF Library > Create and type the name [hot-nozzle].

2. Click Subordinate > Done for the dependency option.

3. Pick the cut and hole as the features to be included in the UDF.

4. Click Done > Done/Return.

5. Type [nozzle sketching plane] at the prompt for theFRONT datum plane.

6. Both features reference the top of the block. Click Single >Done/Return to use a single prompt for both features.

7. Type [nozzle placement plane] at the prompt for thehighlighted surface.

8. Type [nozzle mid plane] at the prompt for the RIGHT datumplane.

9. Type [gating surface] at the prompt for the bottom of theblock.

10. You now have the opportunity to review the prompts. Click Next >Previous to change any incorrect prompts.

11. When all of the prompts are correct, click Done/Return.

12. Click Var Dims in the dialog box by double clicking on it.

13. Pick the .06 hole diameter as the only variable dimension.

14. Click Done Sel > Done/Return > Done/Return.

15. Type [gate diameter] at the prompt for this dimension.

16. Click OK to create the UDF.

17. Return to the ASSEMBLY menu.

Task 3. Change the symbolic names of some of the dimensions to makeit easier to identify them.

1. Click Modify > Dim Cosmetics > Symbol.


NOTES

2. Pick the cut and the hole to display their dimensions.

3. Pick the 2.00 and 3.00 diameter dimensions and name them[DIA1] and [DIA2], respectively.

4. Pick the 2.375 and 2.625 diameter dimensions and name them[DEPTH1] and [DEPTH2], respectively.

Task 4. Modify the UDF to create a family table with two commonsizes.

1. Click Feature > UDF Library > Modify.

2. Select the HOT-ZOZZLE.GPH in the OPEN dialog box.

3. Double click on the Family Table element in the dialog box.

4. Click Add Item > Dimension.

5. Pick the 3.00 and the 2.00 diameters and the 2.375 and the 2.625depths in this order.

6. Click Done Sel > Done/Return.

7. Click Edit in the FAMILY TABLE menu to display the Pro/TABLEeditor. Fill in the family table as shown in Figure 18.

Figure 18: Family Table for Nozzle UDF

8. Click File > Exit to save and close the table editor.

9. Click Done/Return > OK.

10. Save the model and close the window.


NOTES

EXERCISE 3: Placing UDFs

Figure 19: Hot Nozzle Created Using a UDF

Task 1. Open the mold called UDF_CASING.MFG and place the hot-nozzle UDF in the mold.

1. Open UDF_CASING.MFG.

2. Click Feature > Mold Assem > User Defined and select the HOT-NOZZLE.GPH UDF created in the previous exercise.

3. Select the By Parameter tab in the SELECT INSTANCE dialog box

4. Pick the dia2 dimension (d5) and pick the value of 2.00. Thenozzle with this value is now displayed in the Name list.

5. Click Open.

6. Click Independent > Done to make the new group independent ofthe UDF.

7. Click Same Dims > Done.

8. Type [.05] as the gate diameter.


NOTES

9. Click Normal > Done to define how the invariable dimensions willbe displayed in the mold.

10. For the nozzle sketching plane, pick the MOLD_FRONT datumplane.

11. For the nozzle placement plane, pick the top of the workpiece.

12. For the nozzle mid plane, pick the MOLD_RIGHT datum plane.

13. For the gating surface, pick the flat top of the reference model, asshown in Figure 20.

Note: Make sure you pick the top of the reference part for the up tosurface for the gate, not the bottom of the workpiece.

Figure 20: Gating Surface

14. Click Auto Sel > Confirm > Done for the feature intersection.

15. Accept the default direction for viewing the sketching plane.

16. Click Done to finish the UDF. The model should appear as shownin Figure 21.

Gating surface


NOTES

Figure 21: Finished Hot Nozzle UDF



NOTES

MODULE SUMMARYIn this module, you have learned that:

The Waterline feature enables you to create a waterline circuit in yourmold model. When creating the waterline you can specify one of fourend conditions: None, Blind, Thru, and Thru w/Cbore.

The Runner feature enables you to create standard runner geometry inyour mold model.

The Ejector pin clearance hole feature is a hole feature only in Moldmode. It enables you to specify different diameters through each platethat the hole intersects and it also automatically includes acounterbore.

The User Defined Feature is a feature that you can create from acollection of features (including dimensions and references). A UDFenables you to reuse this group of features in other models to help youincrease your productivity.

1

Module

Parting Surface CreationIn this module, you will learn some of the different methods ofcreating a parting surface. A parting surface is a surface feature,created by the set of techniques that can be used to split either aworkpiece or an existing volume, including surfaces of the referencepart.

Objectives


Explain what a surface feature is in Pro/ENGINEER and how theyare used to build parting surfaces

Create parting surfaces

Manipulate surface features using Merge, Trim, and Extend


NOTES

SURFACE FEATURESSurface features are non-solid features that are extremely thin and havedefined boundaries, as shown in Figure 1. They are listed in the ModelTree with the symbol and can be used for creating solid models,manipulating existing solid geometry and for creating parting surfaces inPro/MOLDESIGN.

Figure 1: Surface Feature

The external edges of surface features are yellow and the internal edgesare magenta. When multiple surfaces are combined or merged, it isreferred to as a surface quilt, as shown in Figure 2.

Figure 2: Surface Quilt

Yellowedge

Magentaedge

Part ing Surface Creat ion Page 4-3

NOTES

A parting surface is a surface quilt that is used to divide the workpiece intoseparate parts, as shown in Figure 3. In Pro/MOLDESIGN, assembly-levelsurface features are used to comprise a parting surface.

Figure 3: Parting Surface

Parting surfaces, despite their name, are actually several features. They aremade up of individual surface features, surface merges, surface trims, andother surface manipulation features.

When creating a parting surface, there are two essential rules that must befollowed for the parting surface to be created successfully:

A parting surface must intersect the workpiece or the mold volumecompletely to be able to perform a split, as shown in Figure 4.

A parting surface may not intersect itself, as shown in Figure 4.

Figure 4: Invalid Parting Surfaces

Creating Surface FeaturesSurface features share many creation options with solid features and havesome that are unique. The surface creation options include the following:

Incomplete Overlapping


NOTES

Extrude - Create the surface by extruding the sketched section to aspecified depth in the direction normal to the sketching plane.

Revolve - Create the surface by rotating the sketched section at aspecific angle around the first sketched centerline.

Sweep - Create the surface as a result of sweeping a sketched sectionalong a specific trajectory.

Blend - Create a straight or smooth blended surface connecting severalsketched sections.

Flat - Create a planar datum surface by sketching its boundaries.

Offset - Create a datum surface by offsetting a surface of the referencepart.

Copy - Create a datum surface by copying surfaces of the referencepart.

Copy by Trim - Create a copy of the trimmed surface.

Fillet - Create a quilt by creating a fillet surface.

Shadow - Create a parting surface and component geometry using alight projection technique.

Skirt - Create a "Swiss cheese" style parting surface by picking datumcurves created using a silhouette curve and identifying the pulldirection. This technique is discussed further in the next module.

Advanced - Create a complex surface (for example, use datum curves,multiple trajectories, and so on).

Figure 5: Surface Features

Extruded

Flat

Revolved


NOTES

Merging Surface PatchesIndividual surface features must be merged to create a single surface quilt.The edges where the surfaces have been merged appear in magenta,indicating that the edge is shared by two surfaces. Because a partingsurface can be a combination of several surface features, merges arenecessary to connect the surfaces into one quilt. There are two methods formerging surfaces:

Join Use this option when two surfaces share a common edge. Thesystem does not have to calculate the surface intersection, making theprocess faster.

Intersect Use this option when two surfaces intersect or cross eachother. Pro/ENGINEER creates the intersection boundary and asks youwhich parts of each surface you want to keep.

Figure 6: Merging Surfaces

Trimming Surface PatchesThe surface trim feature enables you to remove a portion of a surface. Thesurface trim options include the following:

Extrude Trim a surface by extruding a defined shape through the surface.

Merge

Join


NOTES

Revolve Trim a surface by revolving a defined shape through the surface.

Sweep Trim a surface by sweeping a defined shape along a definedtrajectory.

Blend Trim a surface by transitioning among several defined crosssections.

Use Quilt Trim a surface using another quilt or a datum plane.

Use Curve Trim a surface using a datum curve.

Vertex Round Round off the corner vertex of a surface.

Silhouette Trim a surface, keeping only what is visible from a specifieddirection.

Vertex Round Trim

Use Curve Trim

Silhouette Trim

Figure 7: Sample Surface Trims


NOTES

The silhouette trim is useful in mold design because it enables you todetect where the parting line should be on irregularly shaped parts. To dothis, copy all solid surfaces of the reference, create a silhouette trim, andpick a datum plane perpendicular to the pull direction.

Extending SurfacesThe Extend option enables you to extend all or specific edges of theparting surface by a specified distance or up to a selected reference. Theextend is a mold assembly surface feature and can be further redefined.The surface extend options include the following:

Same Srf The extend feature is of the same type as the surface beingextended. The original will be continued past its selected originalboundaries by a specific distance.

Approx Srf A surface is created as a boundary blend.

Along Dir The surface edge is extended in a direction normal to aspecific terminating plane. This option is valid only when combinedwith the Up To Plane.

Tangent Srf The extend feature is a ruled surface that is tangent tothe original surface.

Figure 8: Surface Extends

Original Surface Same Surface

Tangent Surface Along Direction


NOTES

Modifying and Redefining Parting SurfacesMost changes to parting surfaces can be accomplished using options in thePARTING SURF menu. You can add new features (surfaces, merges, trims,and extends) to the parting surface. You can redefine the existing featuresin a parting surface, modify their dimensions, or delete the entire partingsurface and all of its associated features.

These same commands can also be found under the FEAT OPER menu.When you work in the PARTING SURF menu, you are tellingPro/ENGINEER that you want to work on a specific parting surface;therefore, any new features you create are automatically associated withthat parting surface. Also, you will only be able to select featuresbelonging to that particular parting surface when using editing commandssuch as Redefine.


NOTES


The goal of these exercises is to learn how to create parting surfaces.

Method

In the first exercise, you will create a simple planar parting surface on therod mold using the Flat option.

In the second exercise, you will create complex parting surfaces for a four-cavity pen cap mold. This mold requires that three parting surfaces dividethe workpiece into the necessary mold components. To create theseparting surfaces, you must create multiple surface features and mergethem together. The surfaces are created using the Revolve, Extrude, andCopy surface options.

In the final exercise, you will create a parting surface for an irregularlyshaped part. You will first copy surfaces from the reference part and thenextend them to the sides of the workpiece to ensure that the parting surfaceentirely intersects the workpiece.

EXERCISE 1: Creating a Planar Parting Surface

Figure 9: Planar Parting Surface

Task 1. Open the PART_SURF_ROD.MFG mold model and create a flatparting surface that divides the top and bottom halves of the mold.

1. Open PART_SURF_ROD.MFG.

2. Click Parting Surf > Create and type the name [middle].

3. Click Add > Flat > Done.


NOTES

4. Pick the MAIN_PARTING_PLN datum plane for the sketchingplane and accept the default direction for viewing. Pick theMOLD_FRONT datum plane to face the Bottom of the screen.

5. Click in the Intent Manager toolbar or click Sketch > Edge >Use.

6. Click Loop in the TYPE dialog box and pick in the middle of theworkpiece, as shown in Figure 10.

Figure 10: Parting Surface Sketch

7. Close the dialog box.

8. The four edges of the workpiece should be projected onto the

sketching plane. Click . Click OK.

9. Click Done/Return in the SURF DEFINE and PARTING SURFmenus.

10. Click in the toolbar. The BLANK UNBLANK dialog boxappears.

11. Select ROD_WP in the Visible Components list and click Blank >Close. This blanks the workpiece. The part surface and referenceparts should appear as shown in Figure 11.

Figure 11: Parting Surface

Pick inside the workpiece

Partingsurface


NOTES

12. Click in the toolbar.

13. Click the Unblank tab and select ROD_WP in the BlankedComponents list.

14. Click Unblank > Close. This unblanks the workpiece.



NOTES

EXERCISE 2: Creating a Compound PartingSurface

Figure 12: Pen Cap Mold

Task 1. Open the mold called PEN-CAP-MOLD.MFG and create the firstparting surfaces, which are 360 revolved surfaces used to define theshap

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Documents

mold design demo10

mold layout9

mold design course overview9

mold assembly features2

mold volumes directly2

technology drive

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exercise continued1