Professional Documents
Culture Documents
Fundamentals of
Mold Design
Release 2000i2
T009-310-01
Copyright
Fundamentals of Mold Design
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PRINTING HISTORY
Document No. Date
T009-310-01
08/15/00
Description
Initial Printing of Fundamentals of Mold Design for Release 2000i2
Training Agenda
Fundamentals of Mold Design
Day 1
8:30-8:45
8:45-9:00
9:00-10:00
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
2:00-3:15
Exercise
3:15-3:45
3:45-5:00
Exercise
Day 2
8:30-9:00
Exercise (continued)
9:00-9:30
9:30-10:30
Exercise
10:30-10:45 Break
10:45-11:15 Splitting the Mold
11:15-12:00 Exercise
12:00-1:00
Lunch
1:00-1:30
Exercise (continued)
1:30-2:00
2:00-3:45
Exercise
3:45-4:00
Break
4:00-4:30
4:30-5:00
Exercise
Day 3
8:30-9:00
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
1:30-2:30
Exercise
2:30-3:00
3:00-5:00
Exercise
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Table of Contents
Fundamentals of Mold Design
MOLD DESIGN OVERVIEW
1-1
INTRODUCTION ..............................................................................................................1-2
MOLD PROCESS ..............................................................................................................1-2
MODULE SUMMARY......................................................................................................1-5
2-1
SHRINKAGE .....................................................................................................................2-9
Shrinkage Feature ............................................................................................................ 2-10
Shrinkage Formulas ......................................................................................................... 2-11
Shrinkage by Dimension.................................................................................................. 2-11
Shrinkage by Scaling ....................................................................................................... 2-12
Shrinkage Info.................................................................................................................. 2-13
MODULE SUMMARY....................................................................................................2-29
3-1
ASSEMBLY FEATURES..................................................................................................3-2
The Waterline Feature........................................................................................................ 3-2
The Runner Feature............................................................................................................ 3-2
4-1
5-1
6-1
MODULE SUMMARY....................................................................................................6-21
7-1
CREATING VOLUMES....................................................................................................7-2
Gather Feature.................................................................................................................... 7-2
Sketching Volumes ............................................................................................................ 7-5
Reference Part Cutout ........................................................................................................ 7-6
Offset ................................................................................................................................. 7-6
Draft and Rounds ............................................................................................................... 7-7
Attach................................................................................................................................. 7-8
MODULE SUMMARY....................................................................................................7-31
8-1
MODULE SUMMARY....................................................................................................8-17
MOLD LAYOUT
9-1
10-1
DRAFT............................................................................................................................. 10-2
Terminology .....................................................................................................................10-2
Types of Drafts.................................................................................................................10-3
Tips and Techniques for Draft..........................................................................................10-7
11-1
MODULE SUMMARY..................................................................................................11-19
USING PTC.HELP
A-1
B-1
ELECTRONIC SERVICES.............................................................................................B-13
Module
Objectives
After completing this module, you will be able to:
Page 1-1
INTRODUCTION
Pro/MOLDESIGN is an optional module in Pro/ENGINEER that provides
you 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 the
mold after the design model is changed.
MOLD PROCESS
The Pro/MOLDESIGN process consists of the following steps. These steps
will be discussed in detail in this training course.
1. Create a mold model by assembling or creating reference models
and workpieces. The reference model represents the model that is
being molded and the workpiece represents the A and B plates that
are used in the mold model.
2. Create shrinkage on your mold model. Applying shrinkage values
to the reference model increases the models dimensions in
proportion to the amount of shrinkage that occurs during the
molding process.
3. Add gates, runners, and waterlines as mold features. They will be
considered when creating the molded part, as well as for
interference checking during the mold opening process.
4. Define the parting surfaces to split the workpiece into separate
mold volumes.
5. Split the mold volumes based on the parting surfaces. This
produces two mold volumes (core and cavity). A mold volume is a
three-dimensional, enclosed surface quilt with no mass.
6. Extract the mold volumes to produce mold components. Once
extracted, the mold components are fully functional
Pro/ENGINEER parts, which you can bring up in Part mode, use in
Drawings, or machine with Pro/NC.
7. Create the molding that represents the filled mold cavity. The
system creates the molding automatically by determining the
volume remaining in the workpiece after subtracting the extracts.
Pag e 1- 2
8. Define steps for mold opening. Check interference with static parts
for each step. Modify mold components if necessary.
9. Assemble mold base components, if needed. The mold base
components are the standard moldbase library parts that are
obtained from suppliers such as Hasco and DME.
Pag e 1- 3
MODULE SUMMARY
In this module, you learned that:
During the molding process, changes to the design model may occur.
When these changes are made to the design model, they will propagate
throughout all aspects of the design because the model is parametric
and changes are reflected throughout all the intermediate process steps.
Pag e 1- 5
Module
Objectives
After completing this module, you will be able to:
Page 2-1
GETTING STARTED
To begin a new Pro/MOLDESIGN session, click Manufacturing > Mold
in the NEW dialog box, as shown in Figure 1. You have the option of
using a default template for the mold model. This consists of default
datum planes and a coordinate system, saved views, and predefined layers.
Pag e 2- 2
Design Model
Mold Model
Reference Model
Pag e 2- 3
2. Click
and select the design part from the OPEN dialog box.
The CREATE REFERENCE MODEL dialog box opens, as shown in
Figure 4. Click Merge By Ref or Same Model to use the design
part as the reference part. Click Ok .
Pag e 2- 4
3. Click
to designate the reference model origin and orientation.
The GET CSYS TYPE menu appears. A second Pro/ENGINEER
window opens with the reference model in it.
4. Click Dynamic or Standard . If you choose Dynamic , the REF
MODEL 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.
Pag e 2- 5
Workpiece
The workpiece represents the overall volume of the mold components that
directly participate in shaping the molten material (for example, the top
and bottom inserts together). The workpiece can be an assembly of A & B
plates with inserts or simply an insert that is split into multiple
components. The workpiece can have standard overall dimensions to fit in
the standard base, or it can be custom-made to accommodate the geometry
of the design model.
Workpiece
Figure 6: Workpiece
Pag e 2- 6
Orient the workpiece in relation to the mold base parting plane and
pull direction
Save offsets used during the automatic workpiece creation to a file for
future use
Pag e 2- 7
PRO/MOLDESIGN FILES
File Types
When working in Pro/MOLDESIGN, several different files will be
created. The following list shows these files:
Workpiece FILENAME.PRT
Mold Model
The mold model is the top-level manufacturing model. This model is
retrieved into Mold mode and contains all of the information necessary to
regenerate the entire mold. The mold model contains the assembly of all
of the reference parts, workpieces, and mold process information.
Pag e 2- 8
Note:
Whenever you assemble a new model into the mold, you will
need to classify it as a reference model, workpiece, mold base
comp, or general assembly. If general assembly is used, you
will need to classify all of the parts as one of the other three.
Mold Assembly
The mold assembly is the top-level assembly in the mold model. It
contains all reference models, workpieces, and mold base components as
well as all assembly level mold features. The mold assembly is a true
assembly file and is created automatically when the mold manufacturing
model is created. The mold assembly can be retrieved in Assembly mode
as long as the mold model is first in session.
Saving Files
When a mold model is stored, the new versions of the .mfg and .asm
files are written to disk whether or not changes were made to the mold
model. All other components are only stored if they have been changed.
File Management
Like an assembly, it is important to keep all of the files within the mold in
the same directory as the mold file itself. Also, it is important to keep all
common files in a library somewhere (usually write-protected), to keep
them from being inadvertently changed.
SHRINKAGE
Shrinkage is the contraction of the molding as it solidifies and cools.
Applying shrinkage values to the reference model increases the
dimensions of the reference model in proportion to the amount of
shrinkage 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 by
scaling.
Pag e 2- 9
When you click Shrinkage in the MOLD menu, the SHRINKAGE menu
appears with the following commands:
Formula Choose
By Dimension Set
By Scaling Shrink
Shrinkage Feature
When working with a shrinkage feature in a part, remember the following
points:
Pag e 2- 10
When a part has shrinkage information associated with it, the nominal
dimensions are displayed in magenta and the shrink value is displayed
in parentheses, expressed as a percentage (by default), as shown in
Figure 9. The shrink value can only be modified using the
SHRINKAGE menu.
In order to work with shrinkage, all the Dim Bounds must be cleared.
Shrinkage Formulas
There are two formulas for calculating the shrinkage. The system prompts
you for the S value.
1+S
1/(1-S)
Shrinkage by Dimension
When applying shrinkage by dimension in Mold mode, Pro/ENGINEER
places a shrinkage feature in the design model. You will be able to select
the formula you want to use for calculating the shrink and the dimensions
you want to apply the shrink to.
When specifying shrinkage by dimension, keep the following in mind:
Pag e 2- 11
Shrinkage by Scaling
Shrinkage by Scaling creates a new assembly feature called shrinkage
when applied in Pro/MOLDESIGN. Because it creates a feature in
Pro/MOLDESIGN, it will not affect the design model geometry. If there are
multiple reference models within a mold model, the system will prompt
the 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 about
the selected coordinate system. All assembly offset values used in locating
the reference models in the mold will also be shrunk.
Shrinkage by scaling is primarily used for anisotropic shrink as well as for
models that contain imported geometry because this geometry will be
shrunk with a Shrinkage by Scaling feature.
Note:
If Shrinkage By Scaling is applied to the design model in Part
mode, then the shrinkage feature belongs to the design model,
not to the references parts. Shrinkage will be accurately
reflected by the reference part geometry, but it can not be
updated in Pro/MOLDESIGN.
Pag e 2- 12
Shrinkage Info
Clicking Shrink Info in the SHRINKAGE menu brings up an information
window with the following information:
The status of the design model (that is, whether it is shrunk or not
shrunk)
Pag e 2- 13
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to create a mold model by
assembling the reference model and the workpiece using various
techniques. 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 LAYOUT
dialog box. You will assemble the workpiece and apply shrinkage before
continuing with the molding process.
In the second exercise, you will create a single cavity mold and you will
create a custom workpiece from within Mold mode (Figure 13). You will
complete the exercise by adding shrinkage to the model.
In the third exercise, you will further investigate the options in the
reference part layout to create multiple cavities in the mold.
Pag e 2- 15
Pag e 2- 16
Blank the reference parts and assemble the workpiece into the
1. Click
in the toolbar. The BLANK UNBLANK dialog box
appears.
2. Click
to select all of the visible components (that is, the four
reference 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 the
FRONT and MOLD_FRONT datum planes, the yellow sides of the
RIGHT and MOLD_RIGHT datum planes, and the yellow sides of
the TOP and MAIN_PARTING_PLN datum planes.
7. Click OK in the COMPONENT PLACEMENT dialog box.
8. Click
in the toolbar.
Pag e 2- 17
Note:
The workpiece appears in green to identify the workpiece and
distinguish it from the other components. If your workpiece
does not appear green, repaint your screen. If it still does not
appear green, you probably assembled it as a reference part
and 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 By
Dimension type of shrinkage, and add 0.45% shrink to the rod length and
0.15% 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 base
protrusion of the model.
6. Pick the rod length dimension (200.00) and type [0.0045] as the
shrink value.
7. Pick the diameter dimension (10.00) and type [0.0015] as the
shrink value.
8. Click Done in the SHRINK SET menu. Notice in the Message
Window that the reference model automatically gets regenerated.
Task 4.
values.
1. Click Update > No Shrink > Done from the SHRINK BY DIM
menu. Notice in the Message Window that the rod part has been
regenerated with one suppressed feature, the shrinkage feature.
2. Click Shrink Info . The defined shrinkage should be documented
here. Click Close .
3. Click Done/Return from the SHRINKAGE menu.
4. Save the model and erase it from memory.
Pag e 2- 18
Task 1.
model.
Pag e 2- 19
Task 2.
Pag e 2- 20
6. Click OK .
7. Accept [casing_wrk] as the workpiece name. The workpiece
should appear as shown in Figure 16.
Task 3.
Pag e 2- 21
3. Click Done .
4. Click Update > No Shrink > Done to update the design model to
its unshrunk state.
5. Save the model and erase it from memory.
Pag e 2- 22
Task 2.
Assemble the reference part using the reference part layout tool.
2. Click
Pag e 2- 23
Pag e 2- 24
Task 3. Change the orientation of the layout so that half the game pieces
are 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.
2. Click Preview . The model appears as shown in Figure 19.
Task 4.
Pag e 2- 25
Task 5. Change the orientation of the game pieces so that they are
facing outside the circular pattern.
1. Click
Pag e 2- 26
Pag e 2- 27
MODULE SUMMARY
In this module, you learned that:
Pag e 2- 29
Module
Objectives
After completing this module, you will be able to:
Page 3-1
ASSEMBLY FEATURES
In Mold mode, assembly level features are used to create the mold runner
system, waterline circuit, and ejector pin clearance holes. These can be
created using conventional holes, cuts, and slots. There are several
features available in Mold mode, however, that can speed up this process.
None
Blind
Thru
Thru w/ Cbore
Pag e 3- 2
Pag e 3- 3
USER-DEFINED FEATURES
A user-defined feature (UDF) is a collection of features and their
respective dimensions and references that are captured into a group and
saved as a file. Typically, UDF files are saved in a specific directory or
UDF library that can be accessed anytime and be placed onto a model by
specifying new references and dimensions of the features included in the
UDF. It is an effective way to place common features that are used
repeatedly on multiple models.
UDFs are frequently used in Mold mode for runner systems, as these tend
to be very similar from one mold to the next. When creating UDFs to be
used in Mold mode, it is important to only use assembly level features
because the runner system is created at the assembly level.
Creating a UDF
An example of a UDF is the screw boss geometry shown in Figure 4. Once
this geometry is created, we can save it as a UDF and very quickly reuse it
on other models.
Note:
UDFs can be created in Part mode or Assembly mode and can
consist of part or assembly level features. If you are creating a
UDF to be placed in a mold model, you need to ensure that all
of the features in the UDF are assembly level features.
Before creating a UDF, you must model the geometry that you want to
save. It is important to be aware of the parent-child relationships that you
Pag e 3- 4
are creating. Try to minimize the number of references used to create the
geometry by reusing references. For example, use the same plane as the
sketching plane of one feature and as an alignment reference of another.
Creating UDFs
Once you have defined the geometry that you wish to save, the following
general steps are used in creating the UDF:
1. Specify an option for the dependency of the UDF to the original
model.
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.
Standalone
Subordinate
Pag e 3- 5
Selecting Features
The features that you select to be included in the UDF do not have to be
parents and children of each other, although this is often the case. Features
included in an assembly-level UDF must be assembly-level features.
Placement Plane
Side Plane
Front Plane
Pag e 3- 6
Placing a UDF
The 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 when
prompted.
5. Define any optional elements.
After completing these steps, the system will create a group within the
new model containing the features. The group will have the same name as
the UDF.
Pag e 3- 7
Independent
UDF Driven
file.
The new group is associated with the UDF file. If the
UDF file changes, you can update the group in the new model to
reflect the changes.
Same Size
Same Dims
User Scale
Normal
Read Only
Blank
modified.
The dimension will not appear in the model, and thus, cannot
be modified.
Pag e 3- 8
Placement
Page
Side
Plane
Front Plane
You are prompted for values for any dimensions that were chosen to be
variable. It is important to note the positive direction for these dimensions
when entering a value in order to place the UDF in the correct location.
Pag e 3- 9
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to create mold features
including runners, waterlines, and user-defined features.
Method
In the first exercise, you will add runners and waterlines to the four-cavity
rod mold created in the last exercise.
In the second exercise, you will create a UDF of the features that make up
the opening for a hot nozzle. You will create the UDF with two assembly
features that make up the opening. You will also create a family table
within the UDF to create two common sizes.
In the final exercise, you will place the hot nozzle UDF on the
UDF_CASING.MFG mold.
Pag e 3- 11
4. Click
to create a new layer and type the name [def_dtms].
Click OK .
5. Pick the DEF_DTMS layer and click
layer.
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
changes.
. Click
to see the
Pag e 3- 12
8. Remove the appropriate side of the material and revolve the cut
360 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 mold
assembly 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.
Pag e 3- 13
6.
Pick the FRONT datum plane from one of the top reference models
and the FRONT datum plane from one of the bottom reference
models as references.
8. Exit from Sketcher and click Auto Sel > Confirm > Done .
9. Finish the runner by clicking OK in the dialog box.
Task 4.
Pag e 3- 14
4. Pick the MOLD_RIGHT datum plane and the FRONT datum plane
from one of the top model reference parts as references.
5. Sketch a centerline on top of the MOLD_RIGHT datum plan to
assume symmetry. Sketch a single straight line as shown in Figure
11.
6. Exit from Sketcher and click Auto Sel > Confirm > Done .
7. Finish the runner by clicking OK in the dialog box.
Task 5. Create the gates at both ends of the last runner segment using a
trapezoidal 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 the
sketching plane.
4. Pick the FRONT datum plane from one of the top model reference
parts and the edges of the reference parts as shown in Figure 12 as
references.
Pag e 3- 15
6. Exit from Sketcher and click Auto Sel > Confirm > Done .
7. Finish the runner by clicking OK in the dialog box.
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.
Pag e 3- 16
Task 7. Create a set of waterlines on one side of the mold using the
waterline feature.
1. Click Done in the FEATURE OPER menu and click Mold to access
mold 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 the
MAIN_PARTING_PLN datum plane by a distance of [15]. Click
Done .
6. Use the MOLD_FRONT datum plane as the Bottom reference.
7. Pick the bottom and left-hand edges of the workpiece as
references.
8. Sketch the three lines shown in Figure 14.
9. Exit from Sketcher and click Auto Sel > Confirm > Done .
10. Double click the End Condition element in the dialog box.
Pag e 3- 17
11. Pick the two open endpoints of the waterline circuit (defined as
Thru 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 Thru
in Figure 15) and click Done Sel .
15. Click Thru > Done/Return .
16. Pick the three remaining ends (defined as Blind in Figure 15) and
click 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 waterline
circuit should appear as shown in Figure 15.
Blind
Thru
Thru w/Cbore
Task 8.
1. Click Feature Oper > Copy > Mirror > Dependent > Done .
2. Pick the waterline feature.
Pag e 3- 18
Pag e 3- 19
Cut reference
plane and hole
placement plane
Hole axis
Pag e 3- 20
Task 2.
1. Click Feature > UDF Library > Create and type the name [hotnozzle].
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 the
FRONT 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 the
highlighted surface.
8. Type [nozzle mid plane] at the prompt for the RIGHT datum
plane.
9. Type [gating surface] at the prompt for the bottom of the
block.
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 make
it easier to identify them.
1. Click Modify > Dim Cosmetics > Symbol .
Pag e 3- 21
8. Click File > Exit to save and close the table editor.
9. Click Done/Return > OK .
10. Save the model and close the window.
Pag e 3- 22
Task 1. Open the mold called UDF_CASING.MFG and place the hotnozzle UDF in the mold.
1. Open UDF_CASING.MFG.
2. Click Feature > Mold Assem > User Defined and select the HOTNOZZLE.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. The
nozzle with this value is now displayed in the Name list.
5. Click Open .
6. Click Independent > Done to make the new group independent of
the UDF.
7. Click Same Dims > Done .
8. Type [.05] as the gate diameter.
Pag e 3- 23
9. Click Normal > Done to define how the invariable dimensions will
be displayed in the mold.
10. For the nozzle sketching plane, pick the MOLD_FRONT datum
plane.
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, as
shown in Figure 20.
Note:
Make sure you pick the top of the reference part for the up to
surface for the gate, not the bottom of the workpiece.
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 shown
in Figure 21.
Pag e 3- 24
Pag e 3- 25
MODULE SUMMARY
In this module, you have learned that:
The Ejector pin clearance hole feature is a hole feature only in Mold
mode. It enables you to specify different diameters through each plate
that the hole intersects and it also automatically includes a
counterbore.
The User Defined Feature is a feature that you can create from a
collection of features (including dimensions and references). A UDF
enables you to reuse this group of features in other models to help you
increase your productivity.
Pag e 3- 27
Module
Objectives
After completing this module, you will be able to:
Page 4-1
SURFACE FEATURES
Surface features are non-solid features that are extremely thin and have
defined boundaries, as shown in Figure 1. They are listed in the Model
Tree with the
symbol and can be used for creating solid models,
manipulating existing solid geometry and for creating parting surfaces in
Pro/MOLDESIGN.
The external edges of surface features are yellow and the internal edges
are magenta. When multiple surfaces are combined or merged, it is
referred to as a surface quilt, as shown in Figure 2.
Yellow
edge
Magenta
edge
Pag e 4- 2
A parting surface is a surface quilt that is used to divide the workpiece into
separate parts, as shown in Figure 3. In Pro/MOLDESIGN, assembly-level
surface features are used to comprise a parting surface.
Parting surfaces, despite their name, are actually several features. They are
made up of individual surface features, surface merges, surface trims, and
other surface manipulation features.
When creating a parting surface, there are two essential rules that must be
followed for the parting surface to be created successfully:
Overlapping
Incomplete
Pa rt ing Su rf a ce C re ation
Pag e 4- 3
Extrude
Revolve
Sweep
Blend
Flat
Offset
part.
Copy
part.
Copy by Trim
Fillet
Shadow
Skirt
Advanced
Flat
Join
Intersect
Use this option when two surfaces share a common edge. The
system does not have to calculate the surface intersection, making the
process faster.
Use this option when two surfaces intersect or cross each
other. Pro/ENGINEER creates the intersection boundary and asks you
which parts of each surface you want to keep.
Merge
Join
Pa rt ing Su rf a ce C re ation
Extrude
Pag e 4- 5
Revolve
Sweep
Blend
Use Quilt
Use Curve
Vertex Round
Silhouette
direction.
Silhouette Trim
Figure 7: Sample Surface Trims
Pag e 4- 6
Extending Surfaces
The Extend option enables you to extend all or specific edges of the
parting surface by a specified distance or up to a selected reference. The
extend is a mold assembly surface feature and can be further redefined.
The surface extend options include the following:
Same Srf
Approx Srf
Along Dir
Tangent Srf
Original Surface
Tangent Surface
Same Surface
Along Direction
Pa rt ing Su rf a ce C re ation
Pag e 4- 7
Pag e 4- 8
LABORATORY PRACTICAL
Goal
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 the
rod mold using the Flat option.
In the second exercise, you will create complex parting surfaces for a fourcavity pen cap mold. This mold requires that three parting surfaces divide
the workpiece into the necessary mold components. To create these
parting surfaces, you must create multiple surface features and merge
them together. The surfaces are created using the Revolve , Extrude , and
Copy surface options.
In the final exercise, you will create a parting surface for an irregularly
shaped part. You will first copy surfaces from the reference part and then
extend them to the sides of the workpiece to ensure that the parting surface
entirely intersects the workpiece.
Pa rt ing Su rf a ce C re ation
Pag e 4- 9
6. Click Loop in the TYPE dialog box and pick in the middle of the
workpiece, as shown in Figure 10.
Pick inside the workpiece
. Click OK .
11. Select ROD_WP in the Visible Components list and click Blank >
Close . This blanks the workpiece. The part surface and reference
parts should appear as shown in Figure 11.
Parting
surface
Pag e 4- 10
12. Click
in the toolbar.
13. Click the Unblank tab and select ROD_WP in the Blanked
Components list.
14. Click Unblank > Close . This unblanks the workpiece.
15. Save the model and erase it from memory.
Pa rt ing Su rf a ce C re ation
Pag e 4- 11
Task 1. Open the mold called PEN-CAP-MOLD.MFG and create the first
parting surfaces, which are 360 revolved surfaces used to define the
shape of the side action slides.
1. Open PEN-CAP-MOLD.MFG.
2. Click Parting Surf > Create and type the name [side1].
3. Click Add > Revolve > Done .
4. Click One Side > Open Ends > Done .
5. Pick the FRONT datum plane as the sketching plane and accept the
default direction of feature creation. Pick the TOP datum plane as
the Top reference plane.
6. This revolved surface will be for the top, right-hand side pen cap.
Pick the DTM2 datum plane on the reference part and the top edge
of the workpiece as references.
Pag e 4- 12
Click
and pick
this inside arc
8. Close the SKETCHER menu and click 360 > Done > OK .
9. Repeat steps 3-8 for the other pen cap on the top. The two revolved
surfaces are shown in Figure 14.
Pa rt ing Su rf a ce C re ation
Pag e 4- 13
Pag e 4- 14
6. Exit Sketcher and click UpTo Surface for the depth option. Pick
the opposite side of the workpiece from the sketching plane. The
resulting surface is shown in Figure 16.
Pa rt ing Su rf a ce C re ation
Pag e 4- 15
Task 3.
1. Click Merge > Intersect and pick the extruded surface to intersect
with the first revolved surface.
2. In the Primary Quilt Side and Additional Quilt Side sections of the
SURFACE MERGE dialog box, make the appropriate side
selections so that the preview appears as shown in Figure 17. This
is done to determine which portion of the merged surfaces will be
kept.
Pag e 4- 16
3. Click
4. Click Merge > Intersect and pick the revolved surface on the lefthand side.
5. Make the appropriate side selections so that the preview appears as
shown in Figure 18.
Pa rt ing Su rf a ce C re ation
Pag e 4- 17
6. Click
6. Click Done Sel > Done > Done > OK . The inside of the pen cap
was copied using the seed surface and boundary method to create
the copied surface.
Pag e 4- 18
Note:
It is important to click Done twice to create the surface
successfully.
7. Repeat steps 2-6 for the inside of the other pen cap.
Task 5. Add two 360 revolved surfaces and an extruded surface and
merge the resulting surfaces.
1. Click Add > Revolve > Done > One Side > Open Ends > Done .
2. Pick the FRONT datum plane as the sketching plane and accept the
default direction of feature creation. Pick the TOP datum plane to
face the top of the screen.
3. This revolved surface will be for the bottom, right-hand side pen
cap. Specify the bottom edge of the workpiece, axis A_1, and the
silhouette edge of the copied surface as references.
4. Sketch a centerline along axis A_1. Sketch a single straight line
from the corner of the pen cap to the bottom of the workpiece, as
shown in Figure 20.
Pa rt ing Su rf a ce C re ation
Pag e 4- 19
Task 6. Join the insides of the pen cap surfaces with the revolved
surfaces and intersect the revolved surfaces with the extruded surface
using merge features.
1. Click Merge > Join and pick the right-hand revolved surface to
join it to the right-hand copied surface.
2. Click
3. Click Merge > Intersect and pick the extruded surface. Use the
side options in the Primary Quilt Side and Additional Quilt Side
sections to specify which portions of the surfaces to keep.
4. Continue to merge the remaining two surfaces to the base quilt.
5. When you are finished merging the surfaces together, all the
interior edges should appear magenta. Click Done/Return in the
SURF DEFINE menu. The two parting surfaces are shown in Figure
22.
Pag e 4- 20
Pa rt ing Su rf a ce C re ation
Pag e 4- 21
6. Click UpTo Surface for the depth and pick the left side of the
workpiece. Complete the parting surface.
7. Click Done /Return in the SURF DEFINE menu. The three parting
surfaces are shown in Figure 24.
Pag e 4- 22
Task 1.
Create the first of two parting surfaces using the Copy and
Extend options.
1. Open SURFACE_EXTEND.MFG.
2. Create a parting surface called [main].
3. Click Add > Copy > Done .
4. Click Indiv Surfs and pick the three top surfaces of the reference
part as shown in Figure 26.
Pag e 4- 23
Extend to this
side of the
workpiece
Pick this
surface edge
to extend
7. Click Done Sel > Done and pick the right-hand side of the
workpiece to extend the surface up to, as shown in Figure 27.
8. Click Done Extend .
9. Repeat steps 6-8 for the other side of the surface. When you are
finished, the surface should appear as shown in Figure 28.
10. Click Extend > Along Dir > Done > One By One to pick all three
edges that belong to the front chain of edges, as shown in Figure
28.
11. Pick the front side of the workpiece to extend up to.
12. Repeat steps 10-11 for the backside of the parting surface. When
you are finished, the surface should appear as shown in Figure 29.
Pag e 4- 24
Task 2. Create another parting surface that defines the insert for the
underside of the part.
1. Click Blank in the PARTING SURF menu and select the MAIN
parting surface in the NAMES dialog box. Click OK > Done Sel .
2. Create a second parting surface called [insert].
3. Click Add > Copy > Done .
Pa rt ing Su rf a ce C re ation
Pag e 4- 25
4. Click Indiv Surfs and pick the three surfaces on the underside of
the reference part, as shown in Figure 30.
Pag e 4- 26
10. For the depth option, click UpTo Surface and pick the left-hand
side of the workpiece.
Task 3. Add another extruded surface sketched on the bottom and
extruded up to the flat extruded surface you just created.
1. Click Add > Extrude > Done > One Side > Open Ends > Done .
2. Pick the bottom of the workpiece for the sketching plane and
accept the default direction of feature creation. Pick the right-hand
side of the workpiece to face the Bottom .
3. Pick the FRONT and RIGHT datum planes as references.
4. Sketch centerlines on top of both datum planes. Sketch a rectangle
centered on both as shown in Figure 33.
Pa rt ing Su rf a ce C re ation
Pag e 4- 27
5. For the depth, select UpTo Surface and pick the other extruded
surface.
Task 4.
Pag e 4- 28
Pa rt ing Su rf a ce C re ation
Pag e 4- 29
MODULE SUMMARY
In this module, you learned that:
Surface features are used to create the parting surfaces in your mold
models.
When creating a parting surface it must be created so that it is not selfintersecting and so that it completely intersects the workpiece in order
to perform a split on the mold.
Trimming enables you to remove portions of the surface that are not
needed to create the parting surface.
Pa rt ing Su rf a ce C re ation
Pag e 4- 31
Module
Objectives
After completing this module, you will be able to:
Page 5-1
SILHOUETTE CURVES
A silhouette curve is a datum feature that represents the parting line edge.
Its main use is to aid in the creation of parting surfaces. The curve
includes all outer and inner reference part edges seen when looking from a
pull direction. The feature is useful in creating skirt parting surfaces.
To create a silhouette curve, click Feature > Mold Assem > Silhouette
(or click
> Silhouette > Done ) and type the name of the curve. The
Interpretation of Slides
The optional Slides element automatically compensates for undercuts
during silhouette curve creation. It interprets volumes and components
used as slides and creates correct parting lines. It also automatically
excludes unnecessary edges from the parting line.
Gap Closure
Tangency conditions on a design model may cause instantaneous jumps or
gaps to occur in a silhouette curve parting line. Although the silhouette is
correct, the resulting parting surface is sometimes undesirable. For these
cases, silhouette curve functionality now contains an automatic check that
informs you when gaps are found. You can then smooth out the gap by
closing the curve in three ways:
Lower connection
Upper connection
Middle connection
Gap detected
Gap closed to
upper point
Pag e 5- 3
Loop Selection
If the reference part has vertical surfaces to the pull direction, the system
forms curve chains (open or closed) at both upper and lower edges of that
surface. Both curves cannot be used; therefore, you must use the one
needed. For chains with only one solution, no other options are available.
In addition, you have the option to exclude entire loops.
Pag e 5- 4
Extension Control
You can easily control the direction in which the skirt parting surface
extends. You can accept the default found by the system or interactively
determine the new extension direction. Extension direction arrows
automatically display at vertices and selected points. You define the
direction in which surface patches will be extended by picking edges,
planes, and coordinate systems.
Pag e 5- 5
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to create and manipulate a Skirt
surface using a Silhouette curve.
Method
In the first exercise you will create a Silhouette curve as a mold assembly
feature. This curve is used later in the exercise to create the parting surface
using the Skirt option. You will also manipulate the edges used in the
Silhouette curve.
In the second exercise, you will also create a Silhouette curve to create the
Skirt parting surface. You must then modify the extension direction for
some of the boundary points so that the surface can be successfully
created.
1. Open BEZEL.MFG.
2. Click Feature > Mold Assem > Silhouette .
3. Type [sil_curve] as the name of the silhouette curve.
4. Pick the top surface of the workpiece to define the plane that the
direction will be perpendicular to.
5. Click Okay in the DIRECTION menu.
6. Click OK in the dialog box.
7. Blank the workpiece and the reference part. The silhouette curve
appears as shown in Figure 6.
Pag e 5- 7
Pag e 5- 8
1. Click View > Model Tree Setup > Item Display . Click Features
> OK in the MODEL TREE ITEMS dialog box.
2. Right-click on SIL_CURVE in the Model Tree and click Redefine
in the pop-up menu.
3. Click Suspend All in the CHILD OPTS menu.
4. Zoom in on the six holes in the center of the part. The inside
surfaces of these holes are not drafted (that is, they are vertical
with respect to the parting surface). This means that there are two
edges that could have been used to define the silhouette curve.
Pag e 5- 9
Pag e 5- 10
1. Open 0_LEFT.MFG.
2. Click
Pag e 5- 11
Pag e 5- 12
8. Click Pick Many and draw a bounding box around the arrows on
the right-hand side as shown in Figure 13. This selects all of the
boundary curve points enclosed within the box.
Pag e 5- 13
Pag e 5- 14
11. Click Add Pnt Set . You are now going to perform a similar
operation on the left-hand side of the model.
12. Click Pick Many and carefully draw a bounding box around the
arrows on the left-hand side as shown in Figure 15.
Pag e 5- 15
Pag e 5- 16
Pag e 5- 17
MODULE SUMMARY
In this module, you learned that:
In cases where vertical edges are included in the Silhouette curve you
can use the LOOP SELECTION dialog box to define which edge is to
be used.
Pag e 5- 19
Module
Objectives
After completing this module, you will be able to:
Split the mold using either the One Volume or Two Volume Split
option
Classify (as core or cavity) the portions of the mold that can be
split into more then two volumes
Page 6-1
All workpieces
Selected workpieces
split.
Mold volume
pieces.
You also have the option of creating one volume or two.
Pag e 6- 2
Split Classification
When a parting surface splits a mold into more than two volumes, each
volume is classified as either core or cavity. The ISLAND LIST menu,
shown in Figure 3, is used for selecting and unselecting volume islands.
As the cursor is dragged over the island options, the corresponding volume
is highlighted on the model. Selected islands are included in the first
volume; unselected islands are included in the second volume.
Pag e 6- 3
Pag e 6- 4
The current mold volumes are listed at the top of the dialog box. These
can be selected individually or simultaneously to create the associated
mold components. The selected mold volumes appear in the Advanced
section of the dialog box. Here you can specify a name for the extracted
mold components and select a start part.
After a mold volume has been extracted, the mold component is a fully
functional Pro/ENGINEER part.
Note:
Extracted mold volumes are only stored in the In Session
memory until the mold file has been saved to the disk. It is
important to remember this so you do not lose any of your
work when exiting a session of Pro/ENGINEER.
Pag e 6- 5
MOLDING
Pro/MOLDESIGN enables you to create a molding by simulating the
filling of the mold cavity through the sprue, runners, and gates. It can only
be created after the extract components have been created. The molding
component is created by determining the volume remaining in the
workpiece after subtracting the extracts. This process creates a
Pro/ENGINEER part for which you can calculate mass properties, check
for suitable draft, generate a mesh for flow analysis, and so on.
Molding
Figure 5: Molding
MOLD OPENING
Simulation of a mold opening process enables you to check the suitability
of your design. You can specify moves for any member of the assembly,
except the reference model, the workpiece, or die block. Actually, it is
convenient to blank the reference model and the workpiece before opening
the mold or die.
Pag e 6- 6
Step 1: Move
Core Pin down
The mold opening process is a series of steps, each containing one or more
moves. A move is an instruction to move one or more members, offsetting
them in a specified direction by a specified value.
Pag e 6- 7
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to split a mold model based on
its parting surfaces.
Method
In the first exercise, you will split the rod mold into two volumes using the
flat parting surface created earlier. You will then extract the resulting mold
volumes to create solid parts. You will also create a molding of the
assembly features as well as create the mold opening.
In the second exercise, you will initially split the mold into two volumes
using the MAIN parting surface. You will then split the lower volume into
two volumes using the INSERT parting surface. To complete the exercise
you will extract the mold volumes.
In the third exercise, you will split the pen cap mold. To do this you will
first create the two volumes for the slides using the two parting surfaces,
SIDE_1 and SIDE_2. This is done so that when you perform the main
cavity-core split, the slides will not be divided into two pieces. You will
use the MAIN parting surface for the final split and then you will extract
the volumes.
In the final exercise you will split the casing mold into the core and cavity
volumes based on the MAIN parting surface. When the split is performed,
the workpiece will be divided into three volumes. Since a split can only
create two volumes, you will classify each volume as belonging to the first
or second volume. To complete the exercise you will extract the two
volumes.
Pag e 6- 9
Pick the
MIDDLE
parting surface
3. Click the arrow in the Advanced title bar to expand that section of
the dialog box.
4. Select ROD_A in the advanced section.
5. Click
in the Advanced section and select START_PART.PRT.
The features and the setup (for example, saved views and layers) of
this part will be added to the extracted component for ROD_A.
6. Click Ok in the CREATE MOLD COMPONENT dialog box.
Pag e 6- 10
Pag e 6- 11
13. Click Done/Return in the MOLD OPEN menu. The model returns
to the unexploded state. You can return to the defined mold
opening at any time.
14. Save the model and erase it from memory. The ROD_A.PRT,
ROD_B.PRT, and ROD_MOLDING.PRT components are
automatically saved.
15. Open ROD_A.PRT and ROD_B.PRT. Notice that ROD_A.PRT
contains default datum planes and a coordinate system, whereas
ROD_B.PRT does not. This is because of the start part you copied
from while creating ROD_A.PRT.
16. Erase the parts from memory.
Pag e 6- 13
Pag e 6- 14
Task 2.
1. Click Split > Two Volumes > Mold Volume > Done .
2. Select the SURF_CORE_TMP volume in the NAMES dialog box.
3. Pick the INSERT parting surface, as shown in Figure 13, and click
Done Sel > OK .
Pag e 6- 15
Pag e 6- 16
3. Blank the workpiece, reference part, and parting surfaces to see the
extracted components clearly.
4. Save the model and erase it from memory.
Pag e 6- 17
Task 2. Create the other slide action mold volume by doing a twovolume split of the TEMP_A volume.
1. Blank the workpiece.
Pag e 6- 18
2. Click Mold Volume > Split > Two Volumes > Mold Volume >
Done .
3. Select TEMP_A in the selection box.
4. Select SIDE_2 as the parting surface. Click Done Sel > OK .
5. Name the first volume [slide_2] and the second volume
[temp_b].
Task 3. Create last split to divide the A and the B sides apart using the
MAIN parting surface.
1. Click Split > Two Volume > Mold Volume > Done .
2.
Pag e 6- 19
Casing_core
(Isalnd 2 and
Island 3)
Pag e 6- 20
MODULE SUMMARY
In this module, you learned that:
A mold can be split into its volumes using the parting surfaces that
have been created in the mold model. The system calculates the
amount of workpiece volume to one side of the parting surface and
turns it into a mold volume. The same is done on the other side of the
parting surface.
Once the mold is split you can extract the mold volumes to create
mold components that are stored in the current working directory.
Pag e 6- 21
Module
Objectives
After completing this module, you will be able to:
Page 7-1
CREATING VOLUMES
Gather Feature
The gather feature enables you to quickly define the shape of a mold
volume by collecting surfaces of the reference model and then capping
these surfaces to define the enclosed volume, as shown in Figure 1. If the
reference model changes, the gather also updates on regeneration,
eliminating the need to update the volume manually.
A gather feature can be created using the following steps:
1. Select the surface.
2. Modify the selected quilt (optional).
3. Close the volume.
Reference Model
Gathered Volume
Selecting Surfaces
The first step in creating a gather is selecting the surfaces off the reference
model to define the basic shape of the desired mold volume. There are two
methods of picking surfaces:
Pag e 7- 2
Surfaces
Note:
Only one selection method can be used in a single gather
feature.
Modifying the Base Quilt
Once you have selected the surfaces in the reference model, there are two
tools for modifying the resulting quilt:
Exclude
Fill
The Fill option can be used with the surface and boundary selection
method to keep the selection from growing too large when there are holes
Pag e 7- 3
in one of the selected surfaces. This can keep you from having to select
many boundary surfaces, as shown in Figure 4.
Pag e 7- 4
Sketching Volumes
The shape of a mold volume can also be defined by sketching, as shown in
Figure 6. When you click Sketch as the option for modifying a mold
volume, you are given the option of adding volume or removing volume.
If you choose to add volume, you will create an assembly level protrusion
and if you choose to remove it you will create an assembly level cut.
Extrude this
rectangle across
the workpiece
When you choose to create a sketched feature within a mold volume, you
have the same options as for all sketched features (for example, extrude,
revolve, sweep, and so on). These options work the same as for any other
sketched feature. The only difference when creating a mold volume
sketched feature is that you must sketch a closed section.
Mold Vo l u mes C r eated D irect ly
Pag e 7- 5
Offset
Surfaces in an existing volume can be offset to enlarge certain areas of the
volume. When creating an offset feature, you can choose the surfaces to be
offset and how they will be offset. There are two methods of offsetting the
volume:
Pag e 7- 6
Horizontal
Tangential
Tangential Offset
Original Volume
Horizontal Offset
Pag e 7- 7
Attach
Sometimes, when creating a mold, you end up with more mold volumes
than are needed. If the design intent changes, you may require one mold
volume where you previously required many. You can combine two mold
volumes using an attach feature.
When creating an attach feature, you are prompted to select a base volume
and a volume to attach to it. The second volume will be completely
consumed. The resulting volume will have the name of the base volume
and the shape of the two volumes combined.
Pag e 7- 8
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to create mold volumes directly
from the model using sketching and gathering techniques.
Method
In the first exercise, you will create the mold volume representing the core
of a mold using gather and sketch methods. You will use this mold volume
to split the workpiece and extract the cavity volume.
In the second exercise, you will create a mold for a remote housing. You
will create the core volume using gather and sketch options. You will then
create a second volume representing the slide for the antenna housing. To
complete the exercise you will use these volumes to split the workpiece
into extractable volumes.
In the final exercise, you will again use mold volumes created directly to
split the workpiece into extractable components.
7.
Pick any inside surface on the reference model as the seed surface,
as indicated in Figure 10.
Pag e 7- 9
Fill Surface
Seed Surface
Cap Plane
Boundary Surface
Pag e 7- 10
14. Click Done > Done/Return > Done to create the volume. The
volume should appear as shown in Figure 11.
Task 2. Add to the existing volume that you just created by extruding
another volume from the bottom of the workpiece to create a base for the
core.
1. Click Sketch > Add > Extrude > Solid > Done .
2. Click One Side > Done and pick the bottom of the workpiece as
the sketching plane.
3. Make the direction of feature creation point towards the top of the
workpiece.
4. Click Top and pick the FRONT datum plane on the workpiece.
Pag e 7- 11
5. Click
> Loop
6. When finished with the sketch, use an UpTo Surface depth option
and pick the bottom of the reference model as the depth surface.
7. Click OK to create the feature.
8. Click Done/Return . The volume should appear as shown in Figure
12.
Task 3.
1. Click Split > One Volume > All Wkpcs > Done .
2. Pick the MOUNT_CORE volume as the surface to split the
workpiece and click Done Sel .
3. Click Island1 to include the upper half of the volume and click
Done Sel > OK.
Pag e 7- 12
Pag e 7- 13
7. Once you have finished selecting these surfaces, click Done Sel >
Done Refs > Done/Return to finish the surface and boundary
selection.
Pag e 7- 14
Task 2. Cap all of the open loops at the top of each key opening, the
display opening, and the bottom of the remote.
1. Select Cap Plane and Sel Loops as the first cap options and click
Done .
2. Pick the top face of the remote around the button openings as
shown in Figure 15.
3. Pick an edge off of each button opening as the loops to cap to the
selected plane. Click Done Sel .
Note:
You only need to pick one edge of each loop to select the loop.
4. For the next cap, accept the defaults of Cap Plane and Sel Loops
and click Done .
Pag e 7- 15
5. Pick the top face of the remote around the display opening as the
cap plane.
6. Pick any one of the edges of the display opening as the loop to cap.
Click Done Sel .
7. For the last cap, accept the defaults of Cap Plane and Sel Loops
and click Done .
8. Pick the bottom of the workpiece as the plane to cap the volume.
9. Pick any one of the inside edges on the bottom of the remote as the
loop to cap to the plane. Click Done Sel .
10. Now that all of the open loops have been capped, click
Done/Return > Done to create the feature. The gathered volume
should appear as shown in Figure 15.
Pag e 7- 16
Task 3. Create an extruded volume for the core side to be added onto
the gathered volume. This will act as a base for the core volume.
1. Click Sketch > Add > Extrude > Solid > Done .
2. Click One Side > Done and pick the right-hand side of the
workpiece as the sketching plane.
3. Make sure that the arrow points towards the opposite side of the
workpiece and click Okay.
4. Use the top of the workpiece as the Top reference plane.
5. Sketch the section shown in Figure 16. Make sure you sketch a
closed section.
6. After finishing the sketch, use an UpTo Surface depth option and
pick the far side of the workpiece as the depth plane.
7. Click OK to finish the feature.
Pag e 7- 17
3. Pick the inside of the hole in the antenna post as the axis reference.
Pag e 7- 18
4. Click Done/Sel > Done > Done > Done/Return to return to the
MOLD menu.
Task 5. Create a new volume called slide, which will help create the
geometry for the post at the top of the remote model.
1. Click Mold Volume > Create and type the name [slide].
2. Click Sketch > Extrude > Solid > Done .
3. Click One Side > Done .
4. Pick the top of the workpiece as the sketching plane, making sure
the feature creation points into the workpiece. Pick the front of the
workpiece as the top reference plane, as shown in Figure 19.
Pag e 7- 19
Sketching Plane
Reference Plane
6. After you have finished the sketch, use the UpTo Surface depth
option and pick the top surface of the reference part as the depth
plane. Click OK > Done /Return .
7. Shade the slide volume. Notice that it does not yet reflect the
geometry of the antenna housing.
8. Click Modify and select the name Slide .
Pag e 7- 20
Task 6. The last change to be made to the slide volume will be to round
the top two edges of it. Modify the volume and create a simple edge chain
round on these edges.
1. Click Modify and select the name Slide .
2. Click Round > Simple > Done > Constant > Edge Chain >
Done.
3. Pick the top two edges of the slide volume to round, as indicated in
Figure 22.
Create a round
on these two
edges
Pag e 7- 21
Pag e 7- 22
Pag e 7- 23
Pag e 7- 24
Fill Surface
Boundary
Surface
10. For the close, click Cap Plane > All Loops > Done .
11. Pick the top of the workpiece as the capping plane, as indicated in
Figure 24.
12. Click Done/Return > Done to finish the volume.
Task 2. Add to the HOUSING_CORE volume by sketching an extruded
volume that goes across the workpiece.
1. Click Sketch > Add > Extrude > Solid > Done .
2. Click One Side > Done .
3. Pick the right-hand side of the workpiece as the sketching plane.
4. Make sure the direction is into the workpiece and pick the top of
the workpiece as the Top reference plane.
5. Sketch the section shown in Figure 25.
Pag e 7- 25
6. Use an UpTo Surface depth and pick the opposite side of the
workpiece as the depth plane.
7. Click OK > Done/Return to finish the volume shown in Figure 26.
Pag e 7- 26
Task 3. Create a new mold volume that represents the shape of the core
pin, to be used in hollowing out the center boss.
1. Click Create and type the name [center_pin].
2. Click Sketch > Revolve > Solid > Done .
3. Click One Side > Done .
4. Pick the FRONT datum plane as the sketching plane and the TOP
datum plane as the Top reference plane.
5. Sketch the section shown in Figure 27.
Pag e 7- 27
Pag e 7- 28
7. Include the island representing the bulk of the cavity and neglect
the volume that duplicates the pin.
8. Name the volume [housing_cavity].
Pag e 7- 29
MODULE SUMMARY
In this module, you learned that:
Pag e 7- 31
Module
Objectives
After completing this module, you will be able to:
Page 8-1
Possible Features
Purpose in a Model
Mold Foundation
Runner/Waterline System
Slots
Cuts
Surfaces
Extends
Trims
Parting Surfaces
Merges
Pag e 8- 2
Gathers
Protrusions
Cuts
Rounds
Drafts
Offsets
Reference Part Cutouts
Trims
Trims
Splits
Extracted Components
Molding
Final Components/Details
Moldbase Components
Ej Pin Holes
Pag e 8- 3
B. Delete Extracted
Component
C. Re-Extract Component
MOLD_RIGHT
MOLD_RIGHT
MOLD_RIGHT
MAIN_PARTING_PLN
MAIN_PARTING_PLN
MAIN_PARTING_PLN
MOLD_FRONT
MOLD_FRONT
MOLD_FRONT
MOLD_DEF_CSYS
Reference Models
MOLD_DEF_CSYS
Reference Models
MOLD_DEF_CSYS
Reference Models
Workpieces
Workpieces
Workpieces
Runners
Runners
Runners
Waterlines
Waterlines
Waterlines
Holes
Slots
Holes
Slots
Holes
Slots
Cuts
Cuts
Cuts
Surfaces
Surfaces
Surfaces
Extends
Trims
Extends
Trims
Extends
Trims
Merges
Merges
Merges
Gathers
Protrusions
Gathers
Protrusions
Gathers
Protrusions
Cuts
Cuts
Cuts
Rounds
Rounds
Rounds
Drafts
Offsets
Drafts
Offsets
Drafts
Offsets
Trims
Trims
Trims
Trims
Splits
Trims
Splits
Trims
Splits
Extracted Components
Extracted Components
Molding
Molding
Molding
Moldbase Components
Ej Pin Holes
Moldbase Components
Ej Pin Holes
Moldbase Components
Ej Pin Holes
Cut
Cut
Cut
Extracted Component
Pag e 8- 4
You can perform operations on many features at the same time (copy,
delete, pattern, and so on).
You can organize your model. Local groups appear as a single line in
the Model Tree.
Pag e 8- 5
Pag e 8- 6
part of the parting surface. This menu also contains options for
blanking and unblanking these surfaces.
MOLD COMP Contains the tools for creating and extracting mold
FEATURE OPER Contains operations that are available for all mold
assembly features and so is more general than the PARTING SURF and
MOLD COMP menus. While you should use the PARTING SURF and
MOLD COMP menus whenever possible, the FEATURE OPER menu
contains many tools that are not available in these other menus
(Reroute, Suppress, and so on).
MODEL REGENERATION
When you regenerate a mold model, you can regenerate specific
components or all components, or you can create custom regenerations.
Most mold assembly features affect many different components, so it is
usually necessary to regenerate the entire mold and not just selected
components.
When a change is made to a design model, the change may not
immediately appear in the mold if it uses a reference model instead of the
design model, as shown in Figure 2. In this case, you must regenerate the
reference model so that it updates to the latest design model changes. This
is useful in Mold mode because it gives you a chance to make necessary
changes to the mold before implementing design model changes.
Pag e 8- 7
MOLD INFORMATION
Clicking Info > Mold brings up the MOLD INF dialog box, which enables
you to get information on the bill of materials, components, cavity layouts,
split volumes, created volumes, parting surfaces, and mold construction.
Pag e 8- 8
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to organize the mold model so
that you can better understand the information in the Model Tree. You will
also learn how to use Insert mode to add features earlier in the design.
Method
In the first exercise, you will apply names and group features that have
been created for you in the mold.
In the second exercise, you will use Insert mode to add a runner feature to
the mold before the mold volumes are created. This enables you to include
the runner in the mold volumes.
Pag e 8- 9
Task 2. Create local groups for the secondary runners, gates, and side
parting surfaces.
1. Click Feature > Mold Assem > Feature Oper > Group .
Pag e 8- 10
Pag e 8- 11
Pag e 8- 12
1. Open FEAT_REMOTE.MFG.
2. Unblank the workpiece and reference models.
3. Click Feature > Mold Assem > Feature Oper > Insert Mode >
Activate .
4. Pick FEAT_REMOTE_WP.PRT as the feature to insert after.
Note:
It may be easiest to pick the workpiece using the Model Tree.
Task 2.
Pag e 8- 13
Bottom
reference
Create a make datum
through the bottom surface
of the reference part
Pag e 8- 14
Pag e 8- 15
MODULE SUMMARY
In this module, you learned that:
The order that features are created in your mold is important and will
help you minimize unwanted parent-child relationships.
Insert mode can be used to insert features anywhere in the feature list.
Renaming features can help you easily identify them in the Model
Tree.
Pag e 8- 17
Module
Mold Layout
In this module you will learn about the Mold Layout application.
This application gives you the ability to design multi-cavity molds
directly in Assembly mode.
Objectives
After completing this module, you will be able to:
Page 9-1
MOLD LAYOUT
Mold Layout is an assembly-level application that enables you to design
multi-cavity molds in Assembly mode. To access this application from
Assembly mode, click Applications > Mold Layout in the menubar. The
Mold Layout application in Assembly mode gives you the following
functionality:
cavity population
mold catalogs
Cavity Population
Using the Cavity Layout option in the MOLD LAYOUT menu, you can
access the LAYOUT dialog box. The LAYOUT dialog box, shown in
Figure 1, enables you to quickly populate the mold with multiple cavities.
Pag e 9- 2
The LAYOUT dialog box in the Mold Layout application is similar to the
LAYOUT dialog box available when defining the reference part layout in
Mold mode. The only differences between these two dialog boxes are the
references that are required. You can generate cavity patterns in the same
way as in the reference part definition using the options in the Layout
section of the dialog box.
The first reference required is the Mold/Cast Model. You can select an
existing model or you can create a model on the fly. To create the model,
click
You can also specify an existing mold model template using the Copy
From field or you can create a new model. The new model consists of
default datum planes and a coordinate system. When creating the model
you also have the ability to create a two dimensional curve that defines the
outer extents of the model. This datum curve can be used for
conceptualizing the design or for the creation of the actual geometry.
Mold L ayout
Pag e 9- 3
Once a mold model (that is, a .MFG file) is specified as the cavity, it is
assembled using coordinate systems. One system is used as the mold
cavity origin and the other as the cavity layout origin.
The selection of the mold base is based on vendor, series, width, and
length, all of which are options on the left-hand side of the dialog box. By
selecting a pre-defined mold base its assigned parameters are displayed at
the bottom of the dialog box. You can customize the parameter values by
selecting the value and entering a new value. You can also control the
mold base orientation using the Z-Rotation field in the dialog box.
Pag e 9- 4
Once you have added the injection mold machine to the mold assembly
you can also Replace or Delete the defined machine. The selection of the
injection mold machine is based on the name of the machine, tie bar, and
pressure filters. The parameters defined for the mold machine are shown at
the bottom of the dialog box.
Pag e 9- 5
Pag e 9- 6
Mold L ayout
Pag e 9- 7
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to use the Mold Layout
application in Assembly mode.
Method
In the first exercise, you will enable the Mold Layout application and
define the mold model using the LAYOUT dialog box. You will then
create a datum curve that is later used to create a runner in the mold
model. Next you will define a multi-cavity mold and select the moldbase
from a provided library. The selected moldbase must be modified to
increase the depth of the core plate. To complete the exercise you will add
an injection molding machine.
In the second exercise, you will add an ejector pin set to the assembly by
creating points at the center of edges in the reference model. Once the pins
are created you will trim the pins to the surface of the reference model and
create a clearance cut for each pin in the core.
1. Open MOLD_TOP.ASM.
2. Click Applications > Mold Layout . The MOLD LAYOUT menu
appears.
3. Click Cavity Layout > Create . The LAYOUT dialog box appears.
4. Click
Mold L ayout
Pag e 9- 9
Task 2. Create a projected datum curve to use as a reference for a threedimensional runner.
1. Click
Pag e 9- 10
Mold L ayout
Pag e 9- 11
Pag e 9- 12
Mold L ayout
Pag e 9- 13
Task 3.
Task 4.
1. Click Mold Base > Add . The MOLD BASE SELECTION dialog
box appears.
2. Click HASCO in the Vendor drop-down menu.
3. Click A8x11 in the MOLD BASES menu.
Pag e 9- 14
Core plate is
too small
Pag e 9- 15
Pag e 9- 16
Task 2.
Mold L ayout
Pag e 9- 17
9. Click
and
in the Base Plane section of the dialog box
and pick the bottom side of the ejector retainer plate.
in the Orient Plane section of the dialog box and pick
10. Click
the backside of the ejector retainer plate.
11. Click Preview . You should see eight ejector pins assembled as
shown in Figure 15. If all eight are not present, return to the Point
Feature section of the dialog box and add the appropriate points.
Pag e 9- 18
12. Click Ok .
Task 3.
Mold L ayout
Pag e 9- 19
Task 4.
Pag e 9- 20
MODULE SUMMARY
In this module, you learned that the Mold Layout Application enables you
to do the following directly in Assembly mode:
Mold L ayout
cavity population
mold catalogs
Pag e 9- 21
Module
Objectives
After completing this module, you will be able to:
Page 10-1
DRAFT
The molding process requires that surfaces of the model have draft to
enable part removal from the mold. Draft is a feature that can be created in
Pro/ENGINEER. It is found under the TWEAK menu, which is where all
the surface deformation features are found.
Ideally, draft should be added to the design model before starting a mold.
If this is not possible, however, draft can be added to the reference model
in Mold mode without affecting the design model.
Terminology
In the discussion of draft, several terms will be used:
Pag e 1 0- 2
Draft surfaces
Neutral Plane
Neutral Curve
Reference Plane
Draft Angle
F u n d a m e n t a l s o f M o l d Des i g n
Note:
The draft angle is NOT measured from the original location of
the surfaces; it is measured from the normal vector of the
reference plane.
Neutral plane
remains constant size
Neutral/Reference Plane
Draft direction
indicator
(-10)
(+10)
Draft Surface
Types of Drafts
When creating drafts, you will be given several options. The first option is
whether the draft uses a neutral plane or a neutral curve. Neutral curve
drafts are used when the area you want to remain a constant size is not
planar. The second option is whether the draft angle will be constant or
will vary along the draft surface. Also, for neutral curve drafts that add
draft towards both the core and cavity at the same time, there is the option
to make the two draft angles dependent (the same value in opposite
directions) or independent (separate dimensions).
No Split
Pag e 1 0-3
Neutral
Plane
Neutral
Plane
Pag e 1 0- 4
Split at Sketch
F u n d a m e n t a l s o f M o l d Des i g n
Sketch
Neutral
Plane
No Split
Neutral Curve
(mid-plane remains constant size)
Split at Curve
Pag e 1 0-5
Neutral curve /
split curve
(mid-plane remains
constant size)
Split at Surf
Splitting Surface
Neutral Curves
(top and bottom
remain constant
size)
Pag e 1 0- 6
F u n d a m e n t a l s o f M o l d Des i g n
Place draft features towards the end of the model. Draft is a finishing
feature, used to take a design and make it moldable and should,
therefore, come at the end of the feature list.
Place draft features on the model before rounds. Once an edge has
been rounded, the corresponding surface cannot be drafted, however,
draft can be added first, then the resulting edges rounded.
Draft can be added to shelled parts before the shell feature. The inside
and outside of a shell will both have draft and wall thickness will
remain constant.
If draft fails, try a very small draft angle (.5-1) then work up and
look at where failure occurs.
If draft fails, try creating a cut feature that removes entire model
except area to be drafted then modify the cut so it removes less and
less material and see where the failure occurs.
ROUNDS
Round Types
There are two types of rounds, Simple and Advanced. Simple rounds are
made up of a single set of references, as shown in Figure 8. Advanced
rounds contain multiple sets of references as well as transitions where the
sets come together, as shown in Figure 8.
Simple Round
Advanced round
consisting of two
sound set and a
transition
Pag e 1 0-7
Simple Rounds
To define a simple round, you can use various methods. Regardless of the
method that you choose, you must define the elements to determine the
shape, radius, and robustness of the feature.
Specifying the Radius Value
You can use four different methods for specifying the radius of a round.
There are methods of specifying the radius with numeric input as well as
driving the radius from existing part geometry.
Constant
Variable
Full Round
Through Curve
Full
Variable
To specify the radius of the round for both constant and varying radius
rounds, you can use three methods:
Pag e 1 0- 8
Enter
Pick On Surf
F u n d a m e n t a l s o f M o l d Des i g n
Thru Pnt/Vertex
Edge Chain
One by One
Tangent
Chain
Surf
Chain
Surf-Surf
Edge-Surf
Edge Pair
Pag e 1 0-9
Surf-Surf
This is an optional element that enables you to define the extent of the
round, as shown in Figure 12.
Term Surfs
Auto Blend
- The round geometry will be blended across nontangency conditions of the references.
Terminating Surfaces
Auto Blend
Auto Blend
This is another optional element that lets you determine whether the round
will be created as solid or surface geometry Figure 13.
Pag e 1 0-1 0
Make Solid
Make Surface
Make Surface
Advanced Rounds
An advanced round gives you more flexibility in creating geometry.
Advanced rounds are made up of multiple round sets. Each round set is
created using the same options and attributes of a simple round. The
greatest advantage of an advanced round is that you can specify transitions
between the various round sets. Also, you will be able to combine the
different round options such as surface-surface and edge chain or create
rounds that have multiple radii by combining round sets.
Round Shape and Cross Section
Rolling Ball
Norm To Spine
Circular
Conic
Pag e 1 0-11
Stop
Blend Surfs
Intersect Surfs
Continue
Corner Sphere
Corner Sweep
Patch
Corner Sphere
Corner Sweep
Corner Patch
Pag e 1 0-1 2
Tips on Performance
When creating rounds, keep the following tips in mind:
Use the simplest round option that works. The simpler the round
feature, the quicker the regeneration and the easier it is to troubleshoot.
Remember that simple-edge chain rounds cover the majority of rounds
that most people create.
Troubleshooting Rounds
If you are having trouble creating a particular round feature, try some of
the following troubleshooting techniques:
Create the round as a surface. Using surfacing techniques you can fix
the problem areas manually.
MOLD CHECK
Using the mold check functionality will enable you to analyze the part and
see if it has sufficient draft and the appropriate thickness. Under the mold
check option you can choose either to perform a Draft Check or Thickness
Check on the model.
Draft Check
To check the model for sufficient draft, you will need to specify the
minimum draft angle, a pull direction plane, and whether you want to
Des ign fo r Mold abil ity
Pag e 1 0-13
check for draft on one side or both sides (core, cavity, or both). The pull
direction plane is a plane that is normal to the direction that the mold is
opening.
After specifying the pull direction plane and the draft check angle,
Pro/ENGINEER calculates the draft of every surface relative to the
specified direction. Any surface that is greater than the draft check angle
will appear in magenta, any surface that is less than the negative of the
angle will appear in blue. All surfaces that are in between will appear in a
spectrum of colors that represent the angle, as shown in Figure 16.
3 Draft
10 Draft
No Draft
Thickness Check
You can use the thickness check functionality to determine whether any
areas within the part are too thin or too thick in comparison to the users
specified minimum and maximum thickness. You can either check
thickness at parallel planes incrementally spaced through the part or at
specific planes that you select.
Pag e 1 0-1 4
Pag e 1 0-15
Pag e 1 0-1 6
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to check your design model for
moldability before creating your mold model.
Method
In the first exercise, you will practice creating several types of draft
features.
In the second exercise, you will perform draft checks on a design model
that has had draft already created for you. You will ensure that all surfaces
have the required 2 draft. If any surfaces are below this minimum, you
will modify the model and perform the draft check again.
In the third exercise, you will perform a thickness check on the model to
look for areas that are too thick or too thin. If any problem areas are found,
you will modify the model and verify the results.
Pag e 1 0-17
8. Since this plane will also work as the reference plane, click Use
Neut Pln when prompted to select the plane that the direction will
be perpendicular to.
Neutral Plane
Neutral Plane
Pag e 1 0-1 8
Create draft on the end of the part using the split at plane
Draft Surface
Neutral Plane
Add draft to the other end of the model using the split at sketch
Pag e 1 0-19
4. Pick the opposite end of the part as the draft surface, as indicated
in Figure 23.
5. Click Done .
6. For the neutral plane, pick the top of one of the two small
protrusions on the sides of the part, as indicated in Figure 23.
Draft Surface
Neutral Plane
Create draft on the side of the part using a neutral curve draft.
Draft Surface
Neutral Curve
Pag e 1 0-21
1. Open CASING.PRT.
2. Click Analysis > Surface Analysis .
3. Click Draft Check in the Type drop-down list.
4. In the Surface section of the dialog box, click Part in the dropdown list.
5. When prompted to select a plane to define the pull direction, pick
the TOP datum plane.
6. Click Both Directions .
7. Type [10] as the Draft Angle. This value shows you the surfaces
that have less then a 10 draft on the surfaces of the model.
8. Click Compute to update the display for the new draft angle, as
shown in Figure 26.
Pag e 1 0-2 2
Pag e 1 0-23
Pag e 1 0-2 4
7. Pick the FRONT datum plane as the plane for the slices to be
parallel to.
8. Flip the arrow so it is pointing in the direction of the end point and
click Okay .
9. Type [1.0] as the slice offset.
10. Type [0.5] as the maximum allowable thickness and [0.05] as
the minimum allowable thickness.
Des ign fo r Mold abil ity
Pag e 1 0-25
11. Click Compute to perform the analysis with the current values.
12. Using the up and down arrows in the Results section, step through
all of the cross sections. Notice that the screw bosses are showing
up as below the minimum thickness, as shown in Figure 30.
Task 2. Check for thickness through the large protrusions on the bottom
of the part and the screw bosses using the Select Planes method.
1. Click Planes to use planes to conduct the thickness check.
2. Select RIGHT and FRONT as the reference datum planes.
3. Click Done Sel > Done Plane .
4. Using the up and down arrows in the Results section, notice that in
addition to the thin screw bosses, the rectangular protrusions on the
bottom of the part are too thick, as shown in Figure 31.
Pag e 1 0-2 6
5. Click
Pag e 1 0-27
MODULE SUMMARY
In this module, you learned that:
The molding process requires that draft be added to the design model
so that the model can be removed from the core and cavity. Rounds,
like draft features, can also be added to the design model.
Pag e 1 0-29
Module
Objectives
After completing this module, you will be able to:
Page 11-1
Pag e 1 1- 2
You resume a feature that conflicts with another (for example, an edge
round is resumed after a chamfer has been created on the same edge)
F u n d a m e n t a l s o f M o l d Des i g n
The File drop-down menu becomes unavailable and you cannot save
the model.
Note:
If the environment option, Regen Backup , is turned on, the
system will store a backup model before any regeneration and
then remove the backup after the regeneration is completed.
Pag e 1 1-3
Backup model
Current model
Pag e 1 1- 4
List Changes
Geom Check
Show Refs
Failed Geom
Roll To
F u n d a m e n t a l s o f M o l d Des i g n
Failed Feature
Before failed
feature
Pag e 1 1-5
Restore values. You can restore dimension and parameter values to the
values before regeneration.
Note:
Suppressing features and components is an easy way to exit
the resolve environment, however, you must correct the
problem in order to resume the feature. DO NOT leave
suppressed failed features in the model, as this will lead to
problems in the future.
MOLD ACCURACY
In Mold mode, it is often necessary to change the accuracy of the model.
Some of the reasons for changing the model accuracy are:
Intersecting two models of very different size (that is, through the use
of the merge or cutout commands). For the two models to be
compatible, they should have the same absolute accuracy.
Relative Accuracy
Relative accuracy is the default method of measuring the accuracy in
Pro/ENGINEER. The relative accuracy is calculated by dividing the
smallest edge allowed in the model by the overall size of the model. The
overall size of the model is defined as the diagonal length of the bounding
box of the model.
Pag e 1 1- 6
F u n d a m e n t a l s o f M o l d Des i g n
Model Size
The default relative accuracy for a model is 0.0012. This means that the
ratio of the smallest edge on the model to the size of the model cannot be
smaller than this value. For example, if a model has a size of 1000 mm,
the smallest edge on the model can be 1.2 mm (1.2mm/1000mm=0.0012).
If you are creating very small features, you can increase the accuracy to
0.0001 (0.000001 if the config option accuracy_lower_bound is used).
Note:
Increasing the accuracy results in longer regeneration times
and larger file sizes. You should only increase the accuracy
when you are unable to resolve the problem using other
methods.
Absolute Accuracy
In general, you should use the default relative accuracy whenever possible.
This enables the accuracy to adapt to changes in the size of the model.
Sometimes, however, you need to know the accuracy in absolute units. To
do this, use absolute accuracy. Absolute accuracy is set in the units of the
Pag e 1 1-7
model. For example, if you set the absolute accuracy to 0.001, then the
smallest edge allowed will be 0.001.
Absolute accuracy is primarily used when importing or exporting
information through an IGES file or some other common format. For
example, if you are transferring a file from another package, set the same
absolute accuracy for both systems. This will help minimize errors in the
translation.
Pag e 1 1- 8
F u n d a m e n t a l s o f M o l d Des i g n
LABORATORY PRACTICAL
Goal
The goal of these exercises is to learn how to resolve feature failures after
making modifications to the model.
Method
In this exercise, you will modify the design model for an existing mold.
You will add a pattern of holes in the side of the part. This will cause the
existing gather to fail. You will have to redefine the gather and add
another fill surface to resolve the failure.
Pag e 1 1-9
Task 2.
Pag e 1 1-1 0
Task 3. Open the mold model and regenerate the mold to update the
reference model.
1. Open RESOLVE_HOUSING.MFG.
2. Notice that the holes do not appear in the reference model.
3. Click Regenerate > Automatic . The holes appear but the gather
feature fails, as shown in Figure 6.
Pag e 1 1-11
Task 4.
Determine the reason for the feature failure and fix the problem.
Pag e 1 1-1 2
1. Click Mold Opening . Notice the detail for the holes on the cavity
solid. Click Done/Return .
2. Click Feature > Mold Assem > Feature Oper > Insert Mode >
Activate .
3. Pick the first protrusion (ID 105) as the feature to insert after. You
may need to show features in the Model Tree.
Pag e 1 1-13
Pag e 1 1-1 4
9. When finished with the sketch, click UpTo Surface as the depth
option and pick the inside surface of the reference model (the same
surface that was chosen to fill).
10. Click OK to finish the sketch feature.
11. Click RefPart Cutout to remove the overlapping reference model
geometry from the volume. Click Done /Return .
12. Click Shade and shade the slide volume.
Task 6. Further customize this volume by creating rounds and draft on
the volume.
1. Click Modify and select the name RESOLVE_SLIDE.
2. Click Draft > Neutral Pln > Done > No Split > Constant > Done .
3. Pick the three surfaces shown in Figure 10 as the surfaces to draft.
Click Done .
Pick these
three
surfaces
Pag e 1 1-15
4. For the neutral plane, pick the surface of the mold volume that is
against the reference models side .
5. Click Use Neut Pln when prompted to select the reference plane.
6. Type [-5] as the draft angle and click OK to create the feature.
7. Click Round > Simple > Done > Constant > Edge Chain >
Done .
8. Pick the bottom two edges of the volume to round, as indicated in
Figure 11. Click Done .
Round these
edges
Pag e 1 1-1 6
11. Click Feature > Mold Assem > Feature Oper > Insert Mode >
Cancel and type [Yes] to resume all suppressed features.
Task 7.
1. Click Insert Mode > Activate and select the last split feature (ID
583) to insert after.
Insert after
this split
Pag e 1 1-17
10. Click Mold Comp > Extract and pick the RESOLVE_CAV and
RESOLVE_SLIDE volumes to extract.
11. OPTIONAL: Perform a mold opening to see the final components.
Pag e 1 1-1 8
MODULE SUMMARY
In this module, you learned that:
In the Resolve Environment, you have the options of working with the
current model or the backup model.
You can use the INVESTIGATE menu for diagnosing the failure.
The Fix Model option enables you to work on any feature in the
current model or backup model.
The Quick Fix option provides a shortcut method for working on the
failed feature only.
Pag e 1 1-19
Appendix
Using PTC.Help
PTC is continuing its commitment to provide integral
internet/intranet enhancements through the i-series of software
products, including the innovative changes in this release of PTC
Help.
Objectives
After completing this module, you will be able to:
Page A-1
A new help system with integrated table of contents, index, and search
capability
Also, you can visit the PTC Technical Support Online Knowledge
Database , which features thousands of Suggested Techniques. For more
information, see the Technical Support Appendix.
Pag e A- 2
F u n d a m e n t a l s o f M o l d Des i g n
Usin g PT C. Help
Pag e A- 3
Pag e A- 4
F u n d a m e n t a l s o f M o l d Des i g n
Usin g PT C. Help
Pag e A- 5
Appendix
Objectives
After completing this module, you will be able to:
Page B-1
First Name
LNAME:
Last Name
CALLCENTER:
Tokyo
PHONE:
CONFIG_ID:
NNNNNN
PRODUCT:
MODULE:
XX
PRIORITY:
DESC_BEGIN:
description starts
description continues
description ends
DESC_END
Rand Customers
To open calls by email with RAND, send your questions to
tech.support@rand.com.
Pag e B- 2
F u n d a m e n t a l s o f M o l d Des i g n
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Pag e B- 3
Telephone Call
Web Call
Tech SupportEngineer
creates a call in the database
Investigation
Support Engineer
solves issue or
reports it
to Development (SPR)
SPR
Software Performance Report
SPR fixed from Development
Update CD to customer
Call Priorities:
Pag e B- 4
Extremely Critical
Critical
Urgent
- Work impacted
Not Critical
General Information
- Work stopped
F u n d a m e n t a l s o f M o l d Des i g n
Top Priority -
stoppage.
High -
Medium -
Pro/ENGINEER ,
Please write down your username and password for future reference.
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Pag e B- 5
ONLINE SERVICES
After you have registered you will have full access to all Online Tools.
You can search our Knowledge Base using a Search-Engine. Our Online
Support Applications allow to control the status of Calls (Call Tracker)
and SPRs (SPR Tracker) and to add comments to these. If you add an
comment the Technical Support Engineer assigned to your call will be
notified automatically.
Additionally contact information such as the customer feedback line and
electronic order of software and manuals are available.
The Software Update Tool allows you to request to newest software
updates for any PTC product.
F u n d a m e n t a l s o f M o l d Des i g n
Definitions:
Technical Application Note - A technical document that provides
information about SPRs that may affect more than just the customer
originally reporting an issue. TANs also may provide alternative
Techniques to allow a user to continue working.
TAN -
FAQ
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Pag e B- 7
CONTACT INFORMATION
Internet
Rand Customers
Rand Worldwide customers can visit the following Web site for phone
numbers:
http://rock.rand.com/webtracker/CustomerServicesWorldwide.htm
Pag e B- 8
F u n d a m e n t a l s o f M o l d Des i g n
PTC Customers
PTC Technical Support Worldwide Electronic Services
These services are available seven days a week, 24 hours a day.
URL:
http://www.ptc.com/support/index.htm (Support)
http://www.ptc.com/company/contacts/edserv.htm (Education)
FTP:
ftp.ptc.com
cs-feedback@ptc.com
Phone: Numbers
http://www.ptc.com/cs/doc/feedback_nums.htm
Telephone
For assistance with technical issues contact should be directed through the
Electronic Services noted in the previous section, or through the Technical
Support line as listed in the Phone and Fax Information sections below.
PTC has nine integrated Technical Support Call Centers, in North
America, Europe, and Asia. Our worldwide coverage ensures telephone
access to Technical Support for customers in all time zones and in local
languages.
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Pag e B- 9
800-477-6435
781-894-5332
781-894-5513
Maintenance
888-782-3774
Education
888-782-3773
0800 29 7542
Belgium
Denmark
8001-5593
Finland
0800-117092
France
0800-14-19-52
Germany
0180-2245132
49-89-32106-111 (for Pro/MECHANICA outside
Germany)
Ireland
1-800-409-1622
Israel
Pag e B- 1 0
Italy
800-79-05-33
Luxembourg
0800-23-50
Netherlands
0800022-4519
Norway
8001-1872
Portugal
05-05-33-73-69
South Africa
0800-991068
Spain
900-95-33-39
Sweden
020-791484
Switzerland
United Kingdom
0800-318677
0800-75376
Denmark
8001-5593
Finland
0800-117-092
France
0800-14-19-52
Germany
49 (0) 89-32106-0
Ireland
1800-409-1622
Italy
39 (0) 39-65651
Netherlands
0800-022-0543
Norway
8001-1872
Portugal
05-05-33-73-69
900-95-33-39
Sweden
020-791484
Switzerland
41 (0) 1-8-24-34-44
United Kingdom
0800-31-8677
31-73-644-2705
France
33-1-69-33-65-50
Germany
49 (0) 89-32106-325
Italy
39-039-65-65-652
Cu s t o m e r Su p p o rt I n f o rm a t i o n
39-039-6565-1
Pag e B- 1 1
Spain/Portugal
34-91-452-01-00
Sweden
46-8-590-956-00 (Malmo)
46-8-590-956-46 (Upplands Vasby)
Switzerland
41 (0) 1-820-00-80
United Kingdom
1800-553-565
China*
Hong Kong
800-933309
India*
000-6517
Indonesia
001-803-65-7250
97-2-48-55-00-35
Japan
0120-20-9023
Malaysia
1-800-80-1026
New Zealand
0800-44-4376
Philippines
1800-1-651-0176
Singapore
65-830-9899
South Korea
Taiwan
Thailand
001-800-65-6213
*Note: Callers dialing from India or China must provide the operator with
the respective string:
China
India
MTF8309729
MTF8309752
The operator will then connect you to the Singapore Technical Support
Center.
Pag e B- 1 2
81 (0) 3-3346-8280
Hong Kong
(852) 2802-8982
China
86-20-87554426 (GuangZhou)
86-21-62785080 (Shanghai)
86-10-65908699 (Beijing)
Hong Kong
852-28028982
India
Japan
81-3-3346-8268
Malaysia
03-754 8198
Singapore
65-8309866
South Korea
82-2-3469-1080
Taiwan
886-2-758-8600 (Taipei)
886-4-3103311 (Taichung)
886-7-3323211 (Kaohsiung)
ELECTRONIC SERVICES
Up-to-Date +
Information
Cu s t o m e r Su p p o rt I n f o rm a t i o n
Worldwide
ISO 9000
Certification
Quality Control
System
= Maximum
Productivity
with
PTC
Products
Pag e B- 1 3