UNIGRAPHICS

MOLDWIZARD DESIGN PROCESS

WORKBOOK
September 2002
MT10420 - Unigraphics V18.0.3.2

EDS
Proprietary & Restricted Rights Notices

Copyright

Proprietary right of Unigraphics Solutions Inc., its subcontractors, or its suppliers are included in this
software, in the data, documentation, or firmware related thereto, and in information disclosed
therein. Neither this software, regardless of the form in which it exists, nor such data, information, or
firmware may be used or disclosed to others for any purpose except as specifically authorized in writing
by Unigraphics Solutions Inc. Recipient by accepting this document or utilizing this software agrees
that neither this document nor the information disclosed herein nor any part thereof shall be
reproduced or transferred to other documents or used or disclosed to others for manufacturing or any
other purpose except as specifically authorized in writing by Unigraphics Solutions Inc.

E2002 Electronic Data Systems Corporation. All rights reserved.

Restricted Rights Legend

The commercial computer software and related documentation are provided with restricted rights.
Use, duplication or disclosure by the U.S. Government is subject to the protections and restrictions as
set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation
as prescribed in DOD FAR 227-7202-3(a), or for Civilian Agencies, in FAR 27.404(b)(2)(i), and any
successor or similar regulation, as applicable. Unigraphics Solutions Inc., 10824 Hope Street, Cypress,
CA 90630.

Warranties and Liabilities

All warranties and limitations thereof given by Unigraphics Solutions Inc. are set forth in the license
agreement under which the software and/or documentation were provided. Nothing contained within
or implied by the language of this document shall be considered to be a modification of such warranties.

The information and the software that are the subject of this document are subject to change without
notice and should not be considered commitments by Unigraphics Solutions Inc.. Unigraphics
Solutions Inc. assumes no responsibility for any errors that may be contained within this document.

The software discussed within this document is furnished under separate license agreement and is
subject to use only in accordance with the licensing terms and conditions contained therein.

Trademarks

EDS, the EDS logo, UNIGRAPHICS SOLUTIONSR, UNIGRAPHICSR, GRIPR, PARASOLIDR,

UGR, UG/...R, UG SOLUTIONSR, iMANR are trademarks or registered trademarks of Electronic
Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the
property of their respective owners.
MoldWizard Design Process Workbook Publication History:

Version 16.0.1.3 . . . . . . . . . . . . . . . . . . . . June2000

Version 16.0.2.2 . . . . . . . . . . . . . . . . . . . . August 2000
Version 17.0 . . . . . . . . . . . . . . . . . . . . . . . December 2000
Version 18.0 . . . . . . . . . . . . . . . . . . . . . . . October 2001
Unigraphics NX . . . . . . . . . . . . . . . . . . . . September 2002
 Workbook / Project Introduction

Workbook / Project Introduction

Section 1


1

PURPOSE This workbook provides an opportunity to apply the skills taught

in classroom lectures and activities, without specific detailed
instructions. This will help you to consolidate your skills by
practice in a work like situation, and to identify areas where
further assistance from your Instructor is needed.

Toy Wagon Assembly

You are the mold designer for an injection mold company. Your client has
commissioned you to build a toy wagon.

The assembly part file for this project can be found along the following path:

...\ moldwizd \ wagon \

EEDS
All Rights Reserved
MoldWizard Design Process 1-1
Workbook
 Workbook / Project Introduction

Forward portion

Rear portion of the Bed

1

of the Bed
Seat

Foot
Rest
wheel

Wheel

Axle Frame

The front and rear axles are standard steel parts.

The following parts will need to be molded. These parts and their respective
part files are listed below:

D Axle Frame: mdp_axfram

D Bed: mdp_bed
D Foot Rest: mdp_ftrest
D Seat: mdp_seat
D Wheel: mdp_wheel

EEDS MoldWizard V18.0.3

1-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Mold Project Initialization

Mold Project Initialization

Section 2

This section will address the following tasks for all five molded parts:
D Project Initialization: Units, Project Path and Name.
D Setting the Mold Coordinate System.
D Assigning a Shrinkage Scale Factor.
Defining the Workpiece.


2

D

D Defining the initial Mold Layout.

The following pages will provide the information needed to complete this

multiple Mold Project Initialization process.

Axle Frame Seat

Bed

Foot
Rest
Wheel

EEDS
All Rights Reserved
MoldWizard Design Process 2-1
Workbook
 Mold Project Initialization

Axle Frame

Pivot Boss
Inner Axle Clips

Outer Axle Clips

Steering Hole

Part Name: ...\wagon\mdp_axfram

Units: User Discretion
Project Path: ...\wagon\axfram\
Project Name: Default: mdp_axfram
Mold Coordinate System: Origin: Midpoint of the edge shown.
Orientation: As shown.
Shrinkage Scale Factor: User Discretion
Work Piece: Default Dimensions
Layout: Auto Center

TIP Use Set Project Project Path and Name to locate the project directory
when ever the path differs from the location of the product model.
Directories were created for you to keep each assembly separate from
others; however, remember that you may also create exactly one new
directory by typing a new directory name at the end of the project path.

EEDS MoldWizard V18.0.3

2-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Mold Project Initialization

Seat

Part Name: ...\wagon\mdp_seat

Units: User Discretion

Project Path: ...\wagon\seat

Project Name: Default: mdp_seat

Mold Coordinate System: The center of the outer bottom

diameter of the part, as shown.

NOTE Note: this will require moving the WCS and adopting it as
the Mold Csys. The initial WCS, while close, is not in the
correct position.

Shrinkage Scale Factor: User Discretion

Work Piece: Default Dimensions

Layout: Auto Center

EEDS
All Rights Reserved
MoldWizard Design Process 2-3
Workbook
 Mold Project Initialization

Bed

Part Name: ...\wagon\mdp_bed

Units: User Discretion

Project Path: ...\wagon\bed

Project Name: Default: mdp_bed

Mold Coordinate System: Origin: The center of the diameter

on the surface shown.
Orientation: As shown.

Shrinkage Scale Factor: User Discretion

Work Piece: Default Dimensions

Layout: Auto Center

EEDS MoldWizard V18.0.3

2-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Mold Project Initialization

Wheel

Part Name: ...\wagon\mdp_wheel

Units: User Discretion

Project Path: ...\wagon\wheel

Project Name: Default: mdp_wheel

Mold Coordinate System: Origin: The center of the bottom

diameter as shown.
Orientation: As shown.

Shrinkage Scale Factor: User Discretion

Work Piece: Set X_length and Y_length to

3in. or 75mm.

NOTE A user defined round workpiece of the following

dimensions may also be used:
Diameter: 3in or 75mm
Height: 2in or 50mm

Layout: Auto Center

EEDS
All Rights Reserved
MoldWizard Design Process 2-5
Workbook
 Mold Project Initialization

Foot Rest

ZC

1.0" in ZC
YC
XC

Part Name: ...\wagon\mdp_ftrest

Units: User Discretion

Project Path: ...\wagon\ftrest

Project Name: Default: mdp_ftrest

Mold Coordinate System: Origin: Offset 1.0 inches from the

center of the face as shown.
Orientation: As shown.

Shrinkage Scale Factor: User Discretion

Work Piece: Default Dimensions

Layout: Auto Center

EEDS MoldWizard V18.0.3

2-6 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Patching the Seat Part

Patching the Seat Part

Section 3

In this section you will add Surface and Edge patches to the seat part.

The opening identified as and the two openings identified as will

be formed using a slide mechanism. You will find that auto patch is not
designed to cope with this particular intent, thus, you may add patches
manually:

. . Use Edge Patch as shown on the following page.

. . Use Surface Patch as shown on the following page.

EEDS
All Rights Reserved
MoldWizard Design Process 3-1
Workbook
 Patching the Seat Part

Step 1 Apply a Surface Patch across the two vertical slots on the
inside face of the part.

Shade the part to verify that

these two patches were created.

3 Step 2 Apply an Edge Patch around the closed edge loop shown

below, to create a floor in the Foot Rest opening.

There are eight edges in this closed loop.

floor

This completes Section 3: Patching the Seat Part.

EEDS MoldWizard V18.0.3

3-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Patching the Foot Rest

Patching the Foot Rest

Section 4

In this section you will apply a Solid Patch to the Foot Rest part.

4

Two openings labelled must be patched.

The contours lend themselves nicely to practicing your skills with Solid
Patch.

EEDS
All Rights Reserved
MoldWizard Design Process 4-1
Workbook
 Patching the Foot Rest

Step 1 Use Create Box to generate a rough solid.

Size the Box by selecting the THREE faces shown below:
. . . One face as shown.
. . . Two corresponding faces on either side of the part; only
one is illustrated.

EEDS MoldWizard V18.0.3

4-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Patching the Foot Rest

Step 2 Use Surface Split to refine the shape of the rough solid.
Use the faces indicated below to refine the shape of the box
using Surface Split.

Inside curved face Planar face shown

Planar face (hidden) Planar face with hole
Planar face Planar face (other side)
Outer blend face Outer blend face

EEDS
All Rights Reserved
MoldWizard Design Process 4-3
Workbook
 Patching the Foot Rest

Step 3 Use Solid Patch to unite the patch body (tool) to the part (target).

Step 4 Edge Patch two vertical gaps.

The solid patch leaves two small vertical gaps on either side of
the solid patch. Use Edge Patch to close these gaps.

Tips on this Edge Patch Procedure:

D Select the two edges shown below.

D Choose OK to Bridge Gap.
D Choose Close Loop.

EEDS MoldWizard V18.0.3

4-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Mold Layouts

Mold Layouts
Section 5

The following pages illustrate the mold layout for each of the five molded parts.
Use the figures as a guide to set the csys and create a layout for each.
Axle Frame: Balanced Two Cavity

Bed: Linear Two Cavity

5


EEDS
All Rights Reserved
MoldWizard Design Process 5-1
Workbook
 Mold Layouts

Seat: Linear Two Cavity

Foot Rest: Balanced Two Cavity

EEDS MoldWizard V18.0.3

5-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Mold Layouts

Wheel: Balanced Eight Cavity, Rectangular or Circular

Step 1 Create 8 cavity layout.

5


EEDS
All Rights Reserved
MoldWizard Design Process 5-3
Workbook
 Mold Layouts

(This Page Intentionally Left Blank)

EEDS MoldWizard V18.0.3

5-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Parting Definition and Cavity & Core Creation

Parting Definition and Cavity & Core Creation

Section 6


6

In this section you will complete Parting Line definition and the creation of a
Cavity and Core for all five molded parts.

Axle Frame:
The Axle Frame has a simple parting. Use of Auto Process, Auto Patch, and
accepting system defaults will provide satisfactory results.

EEDS
All Rights Reserved
MoldWizard Design Process 6-1
Workbook
 Parting Definition and Cavity & Core Creation

Wheel:

The Wheel has a simple parting. Use of Auto Process, Auto Patch, and accepting
6 system defaults will provide satisfactory results.

EEDS MoldWizard V18.0.3

6-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Parting Definition and Cavity & Core Creation

Seat:


The Seat has a simple parting. Use of Auto Process and accepting system defaults
will provide satisfactory results. Patching for slides in this part was carried out in 6
Section 3 of this project.

EEDS
All Rights Reserved
MoldWizard Design Process 6-3
Workbook
 Parting Definition and Cavity & Core Creation

Bed:

The Bed parting lies on two different planes joined by a transition section .

Step 1 Define the Parting Line and Auto Patch the Axle Clips.
Begin the parting operation per normal convention.
Use of Auto Process, Auto Patch, and accepting system defaults
will provide satisfactory results.
Upon completing this step, the Parting Lines dialog should be
open, with the parting loop displayed in the graphics screen.

EEDS MoldWizard V18.0.3

6-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Parting Definition and Cavity & Core Creation

Step 2 Use the Edit Transition Curves function to identify the

four curves that link the two parting planes.


6

Step 3 Create Parting Surfaces.

In this step, create the upper and lower Bounded Plane parting
surfaces first.

EEDS
All Rights Reserved
MoldWizard Design Process 6-5
Workbook
 Parting Definition and Cavity & Core Creation

Step 4 Sew the three parting surfaces.

Step 5 Extract the Cavity and Core Regions.

Step 6 Create the Cavity and Core, accept all defaults.

EEDS MoldWizard V18.0.3

6-6 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Parting Definition and Cavity & Core Creation

Foot Rest:

Step 1 Locate crossover faces and subdivide them.
6

Step 2 Search Parting Lines.
Upon completing this step, the Parting Lines dialog should be
open, with the parting loop displayed in the graphics screen.

Step 3 Add four Transition Points:

EEDS
All Rights Reserved
MoldWizard Design Process 6-7
Workbook
 Parting Definition and Cavity & Core Creation

Step 4 Create four Extruded Parting Surfaces.

Step 5 Sew The Surfaces.

EEDS MoldWizard V18.0.3

6-8 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Parting Definition and Cavity & Core Creation

Step 6 Extract the Cavity and Core Regions.

Step 7 Create the Cavity and Core, accept all defaults.
6

Note that the Cavity Body is incomplete in that it does include

the standing steel needed to fill the void seen in the Core Body.

EEDS
All Rights Reserved
MoldWizard Design Process 6-9
Workbook
 Parting Definition and Cavity & Core Creation

Step 8 Unite the Solid Patch Body (tool) that lies on layer 25 to the Cavity
Body (target).

Window to the Cavity part and use Unite in the Modeling

Application to complete this step.

EEDS MoldWizard V18.0.3

6-10 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Seat Slide Head

Seat Slide Head

Section 7

In this section you will create the Slide head that is needed to form openings
that receive the Foot Rest tongue and clips.

. . . The tongue of the Foot Rest slides into this opening.

. . . The Foot Rest clips engage these two slots.

EEDS
All Rights Reserved
MoldWizard Design Process 7-1
Workbook
 Seat Slide Head

Step 1 Create a solid body that will serve as the workpiece for
the Slide Head.
- Open mdp_seat_top, then select Window  More Parts and
open mdp_seat_cavity.

- Create the profile shown below.

D The profile can be created using Sketcher or explicit
curves.

10

1.375" (35mm)
. . . Height to match the top of the tongue opening .

- Extrude the profile into the part a distance of 2.1 Inches or

53 millimeters.

EEDS MoldWizard V18.0.3

7-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Seat Slide Head

Step 2 Use Solid Split to refine the shape of the workpiece into a
finished slide head.
Before Split

Target Body Tool Body

After Split

EEDS
All Rights Reserved
MoldWizard Design Process 7-3
Workbook
 Seat Slide Head

(This Page Intentionally Left Blank)

EEDS MoldWizard V18.0.3

7-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Foot Rest Slide Head

Foot Rest Slide Head

Section 8

In this section you will create a Slide head needed to form the ribbed lower
surface of the Foot Rest.

As the mold opens, slides in the core half need to move in the
directions shown .
Use the Profile Split function to form the needed Slide Head.

Step 1 Window to the Core part and use Profile Split.

- The Core Body will be the target.

- Chain along the profile shown on the following page . .

EEDS
All Rights Reserved
MoldWizard Design Process 8-1
Workbook
 Foot Rest Slide Head

XC

YC

ZC

Step 2 Complete the operation by extruding in the direction

shown , accept the default extrusion length.

EEDS MoldWizard V18.0.3

8-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Foot Rest Slide Head

8

The Slide Head is illustrated in a partly open position.

EEDS
All Rights Reserved
MoldWizard Design Process 8-3
Workbook
 Foot Rest Slide Head

(This Page Intentionally Left Blank)

EEDS MoldWizard V18.0.3

8-4 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 eMold Base and Standard Parts

eMold Base and Standard Parts

Section 9

This section will add Mold Base assemblies and Standard Parts to the cavity and
core bodies of the five ongoing mold projects.

Axle Frame, Bed, Wheel and Foot Rest

Mold Base
For these projects, use any Mold Base you prefer.

Standard Parts
Add standard parts and actions appropriate for each mold design.

Seat
Mold Base
Inch Mold Design: DME Type B
Index 10.875 X 12
AP_h = 4.875
BP_h = 3.375


9
Metric Mold Design: DME Type 2A
Index 2530
AP_h = 106
BP_h = 76

Standard Parts
Add standard parts and actions appropriate for each mold design.

The following page illustrates a dual cam pin slide that may be used.

EEDS
All Rights Reserved
MoldWizard Design Process 9-1
Workbook
 eMold Base and Standard Parts

Dual Cam Pin Slide

9
Design Challenge
Create slides in the axle clip areas of the bed and/or axle frame projects.

EEDS MoldWizard V18.0.3

9-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2
 Final Details of the Tooling Assembly

Final Details of the Tooling Assembly

Section 10

This final section may be used to add details of the mold design that include:

D Gates
D Runners
D Cooling Circuits
D Electrodes

Add these details as time permits. Two examples of Electrode designs for the
Bed project are shown:

Bed Core Electrode

10


EEDS
All Rights Reserved
MoldWizard Design Process 10-1
Workbook
 Final Details of the Tooling Assembly

Bed Cavity Electrode

10

EEDS MoldWizard V18.0.3

10-2 MoldWizard Design Process
Workbook All Rights Reserved Unigraphics V18.0.3.2