MOLD WIZARD

Overview of Mold Wizard
Mold Wizard is an application for the design of plastic injection molds and other types of molds. Mold Wizard's advanced modeling tools for the creation of cavities, cores, sliders, lifters, and sub-inserts are easy to use and provide fast, associative, 3D-solid results. Mold Wizard leverages the full power of Unigraphics NX and uses UG/WAVE and Master Model technologies.

Benefits
Mold Wizard was developed and tested with continuous input from mold designers and manufacturers. This ensures Mold Wizard matches the needs and priorities of mold makers, and meets real world design challenges. Mold Wizard provides design tools and procedures to automate the difficult and complex tasks involved in mold design. It helps you save time throughout the design process while providing full 3D models to manufacturing. If the product design is altered, additional time is saved because changes to the product model are associative to the mold design elements. Parting is the process of creating a core and cavity based on a plastic part model. The parting process is an important part of the plastic mold design, especially for parts with complicated shapes. The Parting module greatly automates this process by providing key automation tools. Furthermore, the parting operation is completely associative to the original plastic model. Mold bases and component libraries are included from a variety of catalogs. Custom components, including sliders and lifters, sub-inserts, and electrodes, are also provided in the Standard Parts module. The Standard Parts module allows you to associatively place components with fitted pockets. Mold Wizard provides a user-friendly way to manage different kinds of standard parts. You can use the standard parts in the library, and customize the standard parts libraries as required.

Prerequisites
To use Mold Wizard effectively, you should be familiar with mold design and possess a working knowledge of the following Unigraphics NX applications and tools.

Model Preparation Geometry Quality
You should carefully inspect the product model before starting a Mold Wizard project. Producing a good quality mold design requires a good quality product model. Before beginning your mold design project, run Examine Geometry on the product model to locate any problem areas and then correct them. The Examine Geometry function is found under the Analysis menu.

Solid or Surface Model
The Mold Wizard parting process can use either a solid model or a sewn set of surfaces that do not form a solid. When possible, use a solid product model because it will produce solid cavity and core models. Solid cavity and core models provide some advantages in drafting and CAM processing. Thererfore, in most cases, it's worth the additional effort to correct product models with geometry problems and sew them into a solid.

Moldability
Some product models do not have correct draft (mold taper) and/or designs for efficient construction of mold shut-off areas. You should correct the product model to have exactly the geometry that you want in the finished cavity and core. Beginning with a corrected product makes the parting process easier and gives you ready-to-manufacture cavities and cores. A final reason to correct the product model is that adding taper to the cavity, core, or electrodes as an afterthought is far more likely to produce errors.

Product Design Advisor
The Product Design Advisor is a useful tool for examining product models. The Product Design Advisor is now available from the Mold Wizard Tools dialog and can be used without initializing a Mold Wizard project. To examine a product model using the Product Design Advisor, open the product model, start Mold Wizard to load the toolbar, pick the Mold Wizard Tools icon, and then click the Product Design Advisor icon.

Starting Mold Wizard in Unigraphics NX
To start Mold Wizard, select Mold Wizard from the Application menu in Unigraphics NX. The Mold Wizard toolbar appears.

Mold Wizard Toolbar The functions available from the toolbar are: • • • • • • • • • • • • Load Product Family Mold Load CSYS Shrinkage Work Piece Layout Tools Parting Mold Base Standard Parts Ejector Pin Slider/Lifter • • • • • • • • • • • • Sub-Insert Gate Runner Cooling Electrode Mold Trim Create Pockets Bill of Material Mold Drawing Casting Process Assistant View Manager Delete Files

Running a Single Mold Wizard Function
You can run any of the Mold Wizard functions by selecting Tools  Mold Design, and then the desired module, such as Layout.

Part-Specific Operations
Mold Wizard functions intended to operate on a specific part or related files are called part-specific operations. Examples of part-specific operations are the Mold Wizard modules for shrinkage, parting, and the mold coordinate system (MCSYS). Part-specific operations are applied to the active part or related files. If you only have one part, then it is automatically the active part. If you have a family mold (more than one part in the mold), you make a part active by selecting the Family Mold icon and then selecting the name of the active part in the Select Plastic Product dialog.

Create Mold Wizard Project
To create a new mold design project, use the Load Product function. To open an existing project, use the conventional File -> Open to load the top component of the project. Recently edited files can be quickly located for opening from File -> Recently Opened Parts.

Load Product
The mold design process begins by loading the product model.

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Select the Load Product icon from the Mold Wizard tool bar to begin a Mold Wizard project. The Open Part File dialog is displayed.

Load Product Icon
Use the Open Part File dialog to locate and select the product model part file. After the product model has been selected, the Project Initialize dialog is displayed.

Loading Multiple Part Models for Family Molds
Mold Wizard provides the capability to create family molds (molds with more than one product model). The procedure for loading the product models for a family mold is as follows: 1. Select the Load Product icon to load the first product model as you would for a project based on a single part. 2. For each additional product model, repeat the Load Product process until all of the family product models have been loaded. Mold Wizard will add these parts into the mold assembly, with a family mold structure under the layout node for each part. The Load Product procedure doesn't involve the Product Initialize dialog while loading the second and later product models, because the units, project path, and project name remain the same. Repeat the loading process until all of the desired product models have been loaded.

Family Mold Overview and Usage
Molds that produce multiple parts of different designs, such as the top and bottom cases of a phone, are referred to as family molds. When you load multiple product models, Mold Wizard automatically arranges family mold projects into assembly structures with separate branches for each part and its related files. The family mold module allows you to select the active part (from parts that have been loaded in the family mold) for the operations that you need to perform.

Family Mold Icon

Loading Product Models for a Family Mold
The procedure for loading the product models for a family mold is as follows: 1. Select the Load Product icon to load the first part model as you would for a project based on a single part. 2. For each additional part, repeat the Load Product process until all of the family parts have been loaded. Mold Wizard will add these products into the mold assembly, with a family mold structure under the layout node for each product model.

Positioning of Family Mold Components
Family members added to a Mold Wizard project are positioned using the MCSYS settings of the active family member.

Active Parts
You can use the family mode function to select a part as the "active part." Part-specific operations will affect only the active part and its related files. For example, to apply a shrinkage value to a particular part in a family mold, set that part as the active part in the family mode before using the shrinkage module to apply the shrink value. To set the active part: 1. Click on the Family Mold icon. The Select Plastic Product dialog is displayed. 2. Select the name of the part that is to be active.

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Removing a Family Part
You can remove a family part as follows: 1. Click on the Family Mold icon. The Select Plastic Product dialog is displayed. 2. Select the name of the family part to be removed. 3. Click the Remove Family Member button. All components of the family product tree will be removed from the layout node of the mold assembly tree.

Mold CSYS Overview
Some product models require repositioning to place them in the correct orientation relative to the mold assembly. The Mold CSYS (coordinate system) function repositions the linked copy of the product model in the shrink part. The use of linked body and assembly repositioning rather than transform operations allows associativity to be maintained.

Mold CSYS Icon

Setting the Mold CSYS
The process to set the Mold CSYS consists of the following operations: 1. Orient (by rotation) the current Y-Z plane of the product model to the X-Y plane of the absolute CSYS. 2. Position (by transformation) the product model (usually centered) on the X-Y plane. To set the Mold CSYS: 1. Pick the Mold CSYS icon from the Mold Wizard toolbar. 2. Use the CSYS Constructor from the WCS->Orient pull-down menus to orient the WCS so the Z+ axis is in the direction of ejection. 3. Position the WCS to locate the X-Y plane at the intended parting plane. 4. Orient the WCS to align the X axis with the part as it will appear in the cavity and core inserts.

Mold CSYS in a Family Mold Setting the MCSYS in a Family Mold
To make adjustments to the Mold CSYS setting of a product model in a Family Mold: 1. Use the Family Mold function to set the desired part as active. 2. Select the Mold CSYS icon. The product node will automatically be set as the displayed part. 3. Reposition the WCS.

Shrinkage Overview and Usage
Shrinkage is a scale factor applied to a product model to compensate for part shrinkage while cooling. You can set or adjust the shrinkage value at any point in the mold design process if you're using associative cavity and core modeling practices. The shrinkage function automatically navigates through the assembly and sets the shrink part as the work part. The scale operation is applied to the geometry-linked copy of the product model in the shrink part.

Shrinkage Icon Edit Scale
The Edit Scale dialog is similar to the Unigraphics NX Scale dialog, which provides three types of scaling: uniform, axisymmetric, and general.

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Applying Shrinkage
To apply shrinkage to the shrink part: 1. Pick the Shrinkage icon from the Mold Wizard toolbar. The Edit Scale dialog is displayed. 2. Select the type of shrinkage you want to apply (uniform, axisymmetric, or general). 3. Select the method of scaling (Point, Vector, or CSYS) depending upon the shrinkage type you selected. • For the Point method, select where you want the points on the model. • For the Vector method, select the direction of scaling on the model. • For the CSYS method, select the axis, changes to axes, and any constraints. 4. Enter the appropriate Scale Factor values for the shrinkage you want. 5. Click OK. Shrinkage will be applied to the shrink part.

Modifying Shrinkage
To modify the shrink factor: 1. Select the Shrinkage icon. The Edit Scale dialog is displayed. The previous values appear in the Scale Factor fields and can be adjusted to new values. 2. Enter the new shrink factors and click OK. The shrink part, cavity, and core are automatically updated (assuming associative procedures were used to model the cavity and core).

Work Piece Overview
The Work Piece function is used to define the cavity and core insert bodies. It allows multiple approaches to define the work piece. The variety of work piece methods are: • • • Automatic work piece created by the Work Piece dialog and built-in functions. Standard parts work piece defined with the Standard Parts Management system. Modeled work piece or imported into the parting part.

Work Piece Icon

Standard Block
The selection of the Standard Block or alternative work piece provides the following. • • • The Standard Block option creates a single body to define both the cavity and core inserts. The Cavity Only and Core Only options allow selection of individual bodies to define either cavity or core inserts. The Cavity Core option allows selection of a single body for both cavity and core inserts.

The Work Piece function also provides the capability to replace the core and cavity bodies with other bodies. For example, to change the work piece body for the cavity, select the Cavity Only option, and you will be prompted to select a body to be used as a cavity. The work piece function replaces the cavity body.

Automatic Work Piece
The automatic work piece function has two methods of controlling the size and positioning of the work piece: • • Distance Allowance Reference Point

The Distance Allowance Method The Distance Allowance method creates an insert box by measuring the product model and suggesting an appropriate size for the mold insert. The suggested sizes are rounded off to dimensions that provide a minimum allowance around the product model. You can adjust the insert to exact sizes as needed.

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Reference Point Method The Reference Point method allows the user to define the work piece by specifying the dimension to each side of the work piece relative to a reference point. The reference point uses the MCSYS by default. However, an alternative reference may be set using the Set Reference Point button and resulting Point Constructor dialog. Layout Overview The Layout function allows you to add, remove, or reposition cavities in the mold assembly structure. The product nodes under the layout component are manipulated in this process. When a cavity is added, an instance of the product sub-assembly tree is added as a child of the layout.

Layout Icon When you begin layout functions, one cavity is highlighted as the initial manipulation cavity. You can select or deselect cavities that you want to reposition.

Types of Layouts
Rectangular Layout Balance Layout The Balance layout option positions multiple instances of the layout node with an X-Y translation and a rotation. The balanced layout is used when each instance of the cavity and core set may use the same runners, gates, cooling, and corner rounding. The Linear layout option positions multiple instances of the layout node with only X-Y translations (no rotation). The linear method is used when the molded parts should be positioned in a parallel orientation (non-rotated).The following figure shows an example of both:

A. Balanced Layout (Identical Cavity Sets) B. Linear Layout (Right and Left Cavity Sets) Balanced and Linear Layouts The options associated with the rectangular balance Option Cavity Number layout are:

1ST Dist. 2ND Dist. Start Layout

Description There are two cavity options in Cavity Number. You can choose between 2 or 4 cavities. The Cavity Number is the layout number for the highlighted cavities. For example, if you want to create a 16-cavity balanced layout, you can create a 4-cavity layout from a single cavity, then select all four cavities and make another 4-cavity layout with this selection. This creates a total of 16 cavities. Displays the distance between two work pieces in the first selected direction. Displays the distance between two work pieces in the direction normal to the selected direction. After you have set the Cavity Number and distance between the work pieces, you can select the Start Layout button. Four arrows are shown on the model. Select one arrow as the 1st distance direction.

Linear Layout The options associated with Linear layout are: Option X Cavity umber X Dist. Y Cavity umber Y Dist. Start Layout Description Number of cavities in the X direction. Distance between the cavities in the X direction. Number of cavities in the Y direction. Distance between the cavities in the Y direction. After you set the above values, select the Start Layout button to generate the layout.

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Circular Layout In Circular layout, the reference point of the selected cavities rotates around the original point of the absolute coordinate system. Depending upon whether you choose Radial or Constant layout, the selected cavities may rotate around their own reference point. Radial Layout In Radial layout, each cavity rotates around the reference point when the cavity is rotated with the absolute coordinate system's original point. The options associated with Circular Radial layout are: Option Cavity Number Start Angle Description Number of cavities in the rotation range. Using the X+ direction as the reference direction, this is the first cavity reference point initialization angle. The first cavity layout orientation is the same as the cavity you selected. The reference point automatically rotates from the X direction of the absolute coordinate system's original point to the start angle value. Rotate range angle value. The distance between the cavity reference point and the absolute coordinate systems's original point. After you have set the above values, select the Start Layout button. You need to select a reference point. The reference point is a point that you select on the cavity. This point is used to determine the distance between the cavity and the absolute coordinate system's original point. It's also used as a self-rotating center.

Rotate Angle Radius Start Layout Reference Point

Constant Layout In Constant layout, the cavities do not rotate with their own reference point in the layout process. The options are the same as the ones for Radial layout.

Mold Tools Overview
Mold Tools helps you create parting geometry, including solid and surface patches, splitting solid bodies, and creating enlarged surfaces. You use these functions to create parting surfaces and solids for internal openings of the product model before doing the external parting.

Mold Tools Icon Mold Tools provides a suite of tools to aid in creating molds for product models. The Mold Tools toolbar displays the tools available.

Mold Tools Toolbar Product models that include openings within the part require you to design a shut off for each opening. There are two patch-up methods for designing shut-offs: • • Sheet patch-up Solid patch-up

Sheet patches are used to model the shut-off surface required to form an opening in a product model. Solid Patches are used to fill a void that will usually have multiple shut-off faces, such as an opening with a snap-latch feature. The solid patch-up method simplifies the product model by filling the opening. The bodies used to fill the openings are automatically geometry-linked to the cavity and core components and can be later united to define the desired shut-off. Trim region patch is another tool used to patch the opening area of the product. You do not need to unite linked geometries of solid patch to core and cavity. You should have a solid patch body trimmed by faces of the opening area to fit the product shape, then use the trimmed region tool to trim the region extracted from the solid patch by a loop of edges or curves. If trim succeeds, the trim region is linked to cavity and core.

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Sheet Patch-Up Tools You create parting surfaces for internal openings with the following Sheet Patch-Up tools: • • • • Surface Patch Edge Patch Existing Surface Enlarge Surface

Solid Patch-Up Tools Solid Patch-up bodies are created and formed by the following process: 1. Use the Create Box icon to create the solid patch-box to fill the open area. 2. Use the Split Solid function to trim the patch-box to fit the product shape, or divide a solid into two associative pieces. 3. Use the Subtract function to fit the patch-box by subtracting the product model from the patch-box with the Retain Tool option. The Subtract function is a convenient way to shape solid patch-boxes. However, you should understand the modeling operations that occur in the background to determine when it's appropriate to use this function. 4. Use the Profile Split function to extrude a profile of edges or curves and use then to trim the patch-box. When the patch-box has been completely shaped to match the product model and form the desired shutoff faces, it's united to the product model with the Solid Patch function. The patch-body is geometry-linked to the cavity and core components on the patch-body layer category. The patch bodies can be united to the cavity or core bodies as needed. Trim Region Patch-Up Tools You use Trim Region Patch to convert solid patch to sheet patch. 1. Use the Create Box icon to create the solid patch-box to fill the open area. 2. Use the Mold Split function or Replace Face function to trim the patch-box to fit the product shape. 3. Use the Profile Split function to extrude a profile of edges or curves and use them to trim the patch-box. When the patch-box has been completely shaped to match the product model and formed the desired shut-off faces, the Trim Region function is used to extract all face of the patch-box to a region and the Traverse function is used to get a loop of edges or curves, and then trim the region by the loop. The patch region is linked to cavity and core to use as a part of the parting surface directly. Create Box The Create Box function creates solid boxes (blocks) that are modified into patch bodies for the Solid Patch parting method. The patch-box is also a convenient way to create geometry for slide-faces or lifterheads.

Create Box Icon The Mold Wizard Tools dialog provides several methods to shape this block to make a plug for holes. A toggle controls whether associative or non-associative methods are available. Creating a Box To create a box: 1. Click the Create Box button. The Create Box dialog is displayed. 2. To define the box, select faces on the product model that you want to be contained by the box. 3. Click the Apply button to create a solid block enveloping the faces that you selected. The Allowance dimension value determines the oversize of the box. You can change the allowance value by dragging the slider to change the temporary box. 4. You can edit the existing box allowance by selecting an existing box. Split Solid

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The Split Solid function lets you break out a section of a cavity or core that will be an insert or slide. The two methods are: • • Target Body Tool Body Split Solid Icon Target Body Selection Both solid body and sheet body can be selected as target body.

Target Body Icon Tool Body Selection

Tool Body Icon Profile Split The Profile Split function is used to split a solid with a set of curves. It can be used to create inserts from the core and cavity inserts.

Profile Split Icon The procedure for Profile Split is as follows: 1. Select a target solid body (usually the cavity or core block). 2. Select a loop of curves/edges. 3. Specify the extrude direction. An extruded surface is created. Solid Patch The Solid Patch function is a method to model shut-off features on open areas on the parting part.

Solid Patch Icon Solid Patch is an alternative to modeling surfaces for shut-offs. Solid Patch is most useful when it's easier to form a solid to fill an opening than to model sheets. An example of a feature that lends itself to using Solid Patch instead of surface patch is most hook latches. The procedure to use solid patch is to first model a solid that fits the opening on the parting part and also has the faces with correct angles for shut-offs. Use the Solid Patch function to unite the shut-off patch body to the parting part model. The Solid Patch function creates a copy of the solid patch body in the cavity and core models on layer 25. Where appropriate, you can unite the solid patch body to the core or cavity body. In some cases, it's preferable to use the patch body as an insert rather than unite it to the cavity or core insert. Surface Patch The Surface Patch function is the easiest patching method to use. It's used for holes fully contained within a single face.

Surface Patch Icon Clicking the Surface Patch icon displays the Select Face dialog. When a face containing holes is selected, Mold Wizard searches for closed edge loops (the holes) within the perimeter of the face, highlights each hole, and asks you to select or deselect the highlighted holes for patching. The selected holes are patched up automatically. In Surface Patch, Mold Wizard extracts a copy of the underlying face for each selected hole, then trims the copy to the hole edges. The patch-up surfaces are copied to CAVITY_SURFACE layer 38 and

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CORE_SURFACE layer 27. The patch-up surface is highlighted when you use the Existing Surface function. Edge Patch The Edge Patch function patches up an open area by selecting a closed curve/edge loop. After selection, Mold Wizard creates a sheet to patch up the open area.

Edge Patch Icon Using Edge Patch To use Edge Patch: 1. Click the Edge Patch icon. Mold Wizard prompts you to select an edge/curve. 2. Selecting an edge displays the Curve/Edge Selection dialog and starts the Traverse Loop menu, which is the same as the Parting Function/Create Parting Lines menu. Mold Wizard guides you by highlighting currently selected curves and the suggested curve, and displays a temporary note, designated as current path, on the graphics window. The dialog changes based on what steps have been performed. 3. After you select a loop, the candidate faces are highlighted and you can select or deselect faces. Edge Patch creates a patch-up sheet based on the following: • If all curves/edges of the loop are on the same plane, a boundary plane is created. • If the loop lies on a face, a surface patch-up algorithm is used. • If the loop crosses two faces, a smart line is created between two faces. Then Enlarge Surface is used to trim and sew the two patch surfaces together. • If the above functions fail and the hole is a feature, feature patch-up is used. 4. The patch-up surfaces are copied to CAVITY_SURFACE layer 38 and CORE_SURFACE layer 27. The patch-up surfaces are highlighted when you select Existing Surfaces. 5. Trim Region Patch The Trim Region Patch function models shut off faces for openings within a product model.

Trim Region Patch Icon Before beginning the trim region patch process the user must create a solid patch body that fits the shutoff opening. The patch body must fill the opening completely to form the shut-off faces. The patch-body has other faces that aren't used to form the shut off and it doesn't matter if these faces are on the core or cavity side of the part as they are trimmed off by the Trim Region Patch function. The Trim Region Patch function procedure is as follows: 1. Select the solid patch body. 2. Select a loop of edges or curves using the Traverse Loop function to form a closed edge/curve chain boundary around the shut-off opening. These edges and curves must contact the patch solid. 3. Accept the trim direction or flip the direction to change the faces from the patch solid that are extracted and trimmed to form the Trim Region Patch faces. A patch feature is created if the trimming operation is successful. Trim patch regions are added to the cavity and core parting regions.

Auto Hole Patch The Auto Hole Patch function automatically finds all internal patch-up loops and patches up all through holes in the product.

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Auto Hole Patch Icon

All Holes Patched Up

There are two methods for searching internal patch-up loops (holes): • • Region Loops Automatic Loops

Region Loops Method The region loops method requires that you first complete the cavity and core regions analysis in the Product Design Advisor (PDA) function. The Auto Hole Patch function just follows the region loops to create patch surfaces. Use the following process during parting to streamline patching loops with cavity and core regions: 1. Use the Product Design Analysis (PDA) function to specify cavity and core regions. 2. Choose the Region loop search method to patch holes (Auto Hole Patch function in Mold Tools). 3. Choose the Extract Region Faces option to extract cavity and core regions (Extract Region Face function in Mold Tools). 4. Extract parting lines by using the Parting Lines, Traverse Loop, Traverse by Face Color option. 5. Create parting surfaces. 6. Go directly to the Create Cavity and Core function in the Parting dialog (skip the Extract Regions function). Automatic Loops Method To patch loops without encountering competing cavity and core regions, the patch function will automatically search for loops. The patch-up loops are highlighted when you start to use this function. You can select loops in Cavity Side, Core Side, or all loops in One by One mode. You can then deselect the highlighted loops. Because some loops cannot be patched up by the surface method, you may need to use another method such as Solid Patch or Trim Region Patch. In these cases, the loops need to be deselected. If you select the One by One option, each loop is highlighted. Click the Auto Patch button and you can decide to patch the highlighted loop, skip it, or extract the loop. If you have already created patched up surfaces and select the Auto Hole Patch function, Mold Wizard prompts you to either delete the patches or keep them.

Using Auto Hole Patch The Auto Hole Patch functionality can be accessed from the Mold Tools toolbar Auto Hole Patch icon or from the Mold Wizard toolbar Parting functionality. When you access it while using Parting, you can use the PDA to define cavity and core regions.

Use Auto Hole Patch From Parting (Region Loops Method)

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Perform the following to access Auto Hole Patch within the Parting function: 1. 2. 3. 4. 5. 6. 7. 8. Pick the Parting icon from the Mold Wizard toolbar. The Parting Functions dialog is displayed. Pick the Parting Lines button. The Parting Lines dialog is displayed. Pick the Auto Search Parting Lines button. The Search Parting Lines dialog is displayed. Select a body using the Select Body button if there is more than one body in the part file. Define an ejection direction with the Eject Direction button or accept the default. Click Apply to initiate the parting lines calculation. Pick the Product Design Advisor button. The Product Design Advisor dialog is displayed. Perform the steps in the PDA Region tab to define the cavity and core regions for the model. Refer to the Product Design Advisor, Region topic for information on using that functionality.

Existing Surface Sometimes the automated features of Sheet Patch Up are not suited for a particular application, for example, when you are working with imported file formats such as IGES, Parasolid, etc. You can also create the surface patch manually using Free Form features or other Unigraphics NX functions. Once created, you can return to the Mold Wizard Tools dialog box and choose Existing Surface, where you're prompted to select the surface you created (or another existing surface you may wish to use). These surfaces are copied to CAVITY_SURFACE layer 38 and CORE_SURFACE layer 2. Later, when you create Core and Cavity, they are highlighted automatically.

Existing Surface Icon You can also use Existing Surface to highlight patched up surfaces to check whether the holes are patched up properly. When you select Existing Surface, all patched-up surfaces are highlighted. You can select new surfaces or deselect existing surfaces to remove them from the existing pool. Parting/Patch Delete The Parting/Patch Delete function lets you delete parting or patched up surfaces, even if a core or cavity has been created. Mold Wizard suppresses the parting features when you delete a parting or patched- up surface.

Parting/Patch Delete Icon Enlarge Surface The Enlarge Surface function is used to extract surfaces from the shrinkage body and enlarge them by controlling the U and V sizes. This allows you to dynamically patch up holes using the U and V sliders.

Enlarge Surface Icon There are two methods to extend the edges of the enlarge feature: • • Linear - Extends the edges of the enlarge sheet linearly. Natural - Extends the edges of the enlarge sheet by following the natural curve of the edges. Natural is the default method.

When you select Enlarge Face from the Mold Tools toolbar, Mold Wizard asks you to select a face. A copy of the face, slightly larger than the selected face, is created. This copy may have slightly different UV parameterization than the original, with the result that certain face types, such as spheres, might have a hole in the center. Maximum Percentage You can change the size of the enlarge surface by dragging the U/V Min/Max sliders. The Maximum Percentage value can be set up to 2000%. This value can be changed during editing of the enlarge surface feature by pressing Enter to confirm.

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Move All Sliders At Once The All option lets control all of the U/V-Min/Max sliders as a single group. When this switch is on and you move any of the individual sliders, all of the sliders move simultaneously, retaining their existing percentage ratios between each other. Trimming the Enlarged Surface Another common use for Enlarge Surface is to create associative parting sheets when there is a surface in the part that can be used for a single contour parting. In this situation, the trim function is especially useful for adjusting an enlarged face to work piece boundaries. There is a Cut to Boundary toggle on the dialog. You can select boundary curves/edges or boundary faces to trim the enlarged surface. Face Split The Face Split function applies split operations on selected faces.

Face Split Icon The following methods are available for splitting faces: • • • Split faces by isocline Split faces by datum plane Split faces by curves

Split Faces by Isocline When you check the Split by Isocline checkbox, only crossover faces can be selected (single/retangular selection). Select the faces to be split by isocline, then click OK or Apply. Split Faces by Datum Plane The datum plane methods provided are: • For face methods: • Selected Faces • Connected Faces For datum plane methods: • The Existing Datum Plane method divides a selected face with a selected datum plane. • The Point + Point method divides a face along a line defined by two opints. • The Point + X-Y Plane method divides a face at the Z-level of a defined point.

Split Faces by Curve The curve methods provided are: • Existing curves/edges • Through two points Trim Solid

Trim Solid is a very powerful tool that allows you to create the sparking area and electrode head automatically. The following images illustrate the intelligence and ease-of-use built into the Trim Solid tool.

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Select a Face

Automatically Generate an Electrode Head

To create the sparking area and electrode head using the Trim Solid tool, do the following: 1. Open the part file that you want to modify with a sparking area and electrode head, for example: To access the Trim Solid tool, select Start→ All Applications and then choose the NX Tooling application you want to use. o If you are using Mold Wizard: On the Mold Wizard toolbar, click Mold Tools and then click Trim Solid o . ,

If you are using Progressive Die Wizard: On the Progressive Die Wizard toolbar, click Progressive Die Tools , and then click Trim Solid .

o

If you are using Electrode Design: On the Electrode Design toolbar,

click Trim Solid.

2. On the Trim Solid dialog, choose Select Face .

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Select Face is the default. Leave the remaining defaults in place. For example: o o o o o The geometry type is set to Face. The initial face option is set to Seed Face. The face configuration is set to Concave. The Search Level is set to 2. The solid creation mode is set to Trim.

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3. To begin creating the sparking area and electrode head, in the graphics window, select a face to establish the initial size and shape of the area.

Select a Face for the Electrode Head

Selected Face Detail

4. Using the initial face as template, the Trim Solid tool automatically searches for adjacent faces, and generates the sparking area. 5. To generate the electrode head, on the Trim Solid dialog, click Apply.

Generated Electrode Head Parting Methods Overview

Electrode Head Detail

Parting is the process of creating a core and cavity based on a plastic part model. The Parting function provides tools to assist in performing parting functions quickly and with associativity. You use the parting functions after you have designed the work piece.

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Replace Solid

To modify a solid using the Replace Solid tool, do the following 1. Open the part model you want to work with, for example:

Sample Part for Replace Solid Procedure

2. To access the Replace Solid tool, select Start→All Applications and then choose the NX Tooling application you want to use. o If you are using Mold Wizard: On the Mold Wizard toolbar, click Mold Tools and then click Trim Solid o . ,

If you are using Progressive Die Wizard: On the Progressive Die Wizard toolbar, click Progressive Die Tools , and then click Replace Solid .

o

If you are using Electrode Design: On the Electrode Design toolbar, click Replace Solid . .

3. On the Replace Solid dialog, choose Select Faces

4. To begin creating the box, in the graphics window, select a face to establish the initial face of the solid.

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Select an Initial Face 5. Select additional faces to complete the shape of the solid.

Select Faces to Define the Shape 6. On the Replace Solid dialog, choose Edit Bounding Box. 7. Change the shape of the solid using the arrow handles or the dynamic input fields.

Edit the Solid

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8. To finish the solid, on the Replace Solid dialog, click Apply.

Apply Changes to Finish the Solid

Extend Solid

To modify a solid using the Extend Solid tool, do the following: 1. Open the part model you want to work with, for example:

Sample Part for Extend Solid Procedure 2. To access the Extend Solid tool, select Start→ All Applications and then choose the NX Tooling application you want to use. o If you are using Mold Wizard: On the Mold Wizard toolbar, click Mold Tools and then click Extend Solid o . ,

If you are using Progressive Die Wizard: On the Progressive Die Wizard toolbar, click Progressive Die Tools , and then click Extend Solid .

o

If you are using Electrode Design: On the Electrode Design toolbar, click Extend Solid .

3. On the Extend Solid dialog, choose Select Face .

.

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4. To modify a solid using the Extend Solid option, in the graphics window, select a face to establish the direction to extend.

Select an Initial Face 5. Do any of the following: o Drag the arrow handle to extend or contract the solid in the face normal direction.

Arrow Handle Moved an Arbitrary Distance o In the Offset Value field, enter a positive or negative value to extend or contract the solid in the face normal direction.

Face Moved Negative Normal o Select Extrude to extend the solid in the face normal direction by adding a Boolean extension to the solid.

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Extruded Extension o In the Draft Value field, in degrees, enter a value to specify the draft angle for the extruded portion of the solid.

Extrusion with Draft Angle

6. To view the results before accepting the box, on the Extend Solid dialog, click Preview. 7. When you are finished, on the Extend Solid dialog, click Apply.

Reference Blend

To generate a blended feature using the Reference Blend tool, do the following: 1. Open the part model you want to work with, for example:

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Sample Part for Reference Blend Procedure 2. To access the Reference Blend tool, select Start→ All Applications and then choose the NX Tooling application you want to use. o If you are using Mold Wizard: On the Mold Wizard toolbar, click Mold Tools and then click Reference Blend o . ,

If you are using Progressive Die Wizard: On the Progressive Die Wizard toolbar, click Progressive Die Tools , and then click Reference Blend .

o

If you are using Electrode Design: On the Electrode Design toolbar, click Reference Blend . selection step.

3. On the Reference Blend dialog, click the Faces

4. In the graphics window, select a curve, blend, or circular object to extract its radius information.

Select a Blend or Cylinder to Extract the Radius 5. On the Reference Blend dialog, click the Edges selection step. 6. On the solid you want to modify, select one or more edges.

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Select One or More Edges to Modify 7. When you have finished selecting edges, on the Reference Blend dialog, click Apply.

Apply the Radius to the Edges

Projection Area

To use the Projection Area tool to extract model data from the faces of a solid, do the following: Calculate the Area of a Solid 1. On the Area Calculation dialog, choose the Select bodies selection step. 2. In the graphics window, select the solid body you want to interrogate. 3. On the Area Calculation dialog, in millimeters, set a tolerance value to define the mesh size. A smaller mesh size results in longer calculation time but gives you a more precise result. 4. Click Apply. When the program is finished, the results are displayed in the Information window. Find the Maximum and Minimum Side Area 1. Choose the Select reference planar face selection step. 2. In the graphics window, select a solid or a sheet body. 3. On the Area Calculation dialog, select Find Maximum and Minimum Side Area.

4. In the Angle Accuracy window, in degrees, specify a rotation angle.

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Visualize a plane running through the Z-Axis. When you define the angle value, you rotate the plane around the axis. Depending on the angle of rotation, the plane projects onto the faces at different angles. The maximum and minimum values are calculated based on the relationship of the Z-plane to the object faces. 5. Click Apply.

Parting Icon

Parting Elements There are several Mold Wizard parting elements:

A. B. C. D. E.

Cavity Block Cavity Trim Sheet Product Model Core Trim Sheet Core Block

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Mold Wizard Parting Elements
Trim Based Cavity and Core Parting Process In trim based cavity and core parting, a set of parting surfaces are created, duplicated, and combined with separated sets of cavity and core faces. The combined sets serve as trimming sheets that form the cavity and core blocks. This method is applicable to both solid models and surface models. Create Parting Overview Create Parting Mold Wizard provides two methods to create parting: • Parting line preference method • Region preference method The parting line preference method starts by searching for parting lines (internal and outer loops of product solid). Then the following patch surfaces, parting surfaces, and cavity/core regions are all created from parting lines. The region preference method starts by searching for cavity/core regions. Then the following parting lines, patch loops, and parting surfaces are all created from the regions. Auto Search Parting Lines In some cases (where the part is conveniently designed for molding), it's possible to automatically find the correct part edges for the parting line. Click the Auto Search Parting Lines button to display the Search Parting Lines dialog. In some cases, you need to select the product model body or define the eject direction. Select Body In some cases, there are multiple bodies in the parting part. The Select Body function allows you to select or deselect a solid body for the search of parting lines. Eject Direction The Eject Direction function displays the Vector Constructor dialog. Using the Vector Constructor, you can define the direction of ejection. Product Design Advisor The Product Design Advisor helps you investigate and find out about the product that is used as a basis for the mold. Complex Parting Lines In cases where the parting geometry is complex or incomplete, it's necessary to use the Split Faces functionality or design some parting lines interactively using the Traverse Loop method. Extract Regions The Extract Regions function performs a single task: extracting core and cavity regions. When you use this function, Mold Wizard automatically searches boundary faces and patched surfaces in the neighborhood of the parting lines. If the total number of faces on the body is not equal to the number of faces that are going to be copied to the core side, plus the number of faces that are going to be copied to the cavity side, then usually boundary faces are not correctly specified. Mold Wizard warns you if such a situation occurs and highlights the problem faces, but you still can ignore the warning and continue extracting. When you extract regions, you have two ways to specify region boundaries: boundary faces and boundary edges. Also, you have the option to edit a seed face for the core region and a seed face for the cavity region.

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Core and Cavity The Core and Cavity function creates two trimming sheets: one for the core, and one for the cavity. When you click the Create Cavity or Create Core buttons, the system pre-highlights and pre-select the parting surface, the core or cavity region, and any patched surfaces. When you exit this dialog, the entire parting is completed. Tolerance controls sewing of trimming sheets. Check Geometry checks body geometry for each sheet that is going to be sewn. If any sheet has invalid geometry, it's highlighted. Check Overlapping checks for and highlights overlapping sheets. When you click Create Cavity, external parting surfaces, patch up surfaces, and cavity regions are highlighted. You can select other sheets or deselect highlighted sheets and sew them together. The trimming sheet is linked to the cavity part and trims the work piece automatically.

Cavity Created The same methods are used to create the core.

Core Created Suppress Parting The Suppress Parting function enables you to make complex changes to a product model after the parting design has been completed. The Suppress Parting edit process applies to the following situations: • • A parting and mold component design has been completed. Changes must be made directly to the product model in the mold design project.

Update Parting In many cases, when you make changes to the product model, Mold Wizard automatically detects the changes and updates the corresponding parting design automatically or interactively (depending on the type of change). Internal Change

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Geometry changes you make to the product model (such as adding bosses, ribs, recesses) that do not change the topology (arrangement of faces or edges) automatically update the mold design. These changes do not involve addition or removal of parting geometry. Any change of this type propagates to the mold design automatically. Add/Remove Holes A hole added to or removed from the product model can be automatically propagated to the mold design. This update process requires that the automated hole-patching routines are applicable to the hole. If the hole requires interactive modeling of the parting surface, the process is semi-automatic. Change Parting Line Changes such as adding or removing notches on the product that cause parting line changes are automatically updatable in some cases, and interactively updatable in others. Whether is can or not be automatically updated is determined by the design change and the parting surface type used. Compare Product Models You use the Compare Product Models function to compare two different versions of a solid model, and to find the differences between them. In Mold Wizard, the Compare Product Models function compares the current model in the product part (which is used in a mold design project) with a new version of the product model. A Mold Wizard project must be open before you can use the Model Comparison function. Swap Product Model Overview The Swap Product Model function handles the situation in which product design changes occur during or after its mold design process. The Swap Product Model function lets you replace the product model used in a mold design project with a new version of the model, and still keep fully association between the existing mold design features (such as tapers, split faces, parting lines, patch surfaces, parting surfaces, etc ) in the mold assembly and new product solid. This swap function is called associative swap, which is useful for cases where the product model for mold design is translated into Unigraphics NX from other CAD systems. Once the product design changes to a new version, it needs to swap the new version for the current version that was used in a Mold Wizard project. Procedure The procedure for swapping an existing product model for a new one is as follows: 1. Load a new version of the product model 2. Edit parting lines, parting surfaces, and patch surfaces 3. Update parting Mold Base Overview The Mold Base function provides configuration of mold bases for Mold Wizard projects and customization of mold base libraries.

Mold Base Icon Mold Base Requirements The requirements for mold base size and configuration vary greatly for different types of projects. To satisfy the specialized requirements of various situations, the Mold Base function includes the following types of mold bases: • • • Standard mold base Interchangeable mold base Universal mold base

Each of these mold base types has different characteristics that make it suitable for some projects and not for others. The following descriptions help select the appropriate type of mold base. Standard Mold Base

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Standard mold bases are used when a standard catalog mold base is required. Standard mold bases are configured from a single dialog. The basic parameters such as mold length and width, plate thickness, and stand-off are easily edited from the Mold Base Management dialog. If your mold design is likely to require a non-standard configuration such as additional plates or repositioned components, the interchangeable mold base is more appropriate. Interchangeable Mold Base Interchangeable mold bases are used when non-standard design options are required. The interchangeable mold base provides a menu of 60 plate-stack configurations. Sub-dialogs are provided for detailed configuration of each component and component set. The interchangeable mold base is based on the dimensions of standard catalogs. However, it may be easily adjusted to non-standard dimensions. If your project requires a configuration that cannot be accomplished with the interchangeable mold base, the universal mold base might be more appropriate. Universal Mold Base The universal mold base is a configurable stack of plain plates that can be arranged to make thousands of combinations. The universal mold base is used when the required mold base configuration is not included in the 60 interchangeable mold base options. User Defined Mold Base If your project requires a mold base that is so unique that it cannot be modeled with the standard, interchangeable or universal mold base, you need to develop your own user defined mold base. If it is unlikely that you will design a similar mold in the future, use interactive Unigraphics NX Modeling to create this unique mold base. If you have ongoing requirements for a mold base that you are going to model, you can add it to the Mold Wizard library for future use. Mold Base Assembly Model Mold Wizard includes a wide (and growing) variety of mold bases. If you have special requirements not covered by standard mold bases, you can design your own custom mold bases and include them in the Mold Wizard Mold Base Management System. Mold Wizard is designed as an open structure so that mold bases can be incorporated and controlled by the Mold Base Management System with no programming required. Modeling methods to create mold bases vary depending on the complexity, configurations, and variety required to model the mold base set. A variety of similar mold base structures can be made from a single assembly model using parameters to control the configurations and dimensions. There are no strict constraints on how to create a mold base assembly model. Following the principles outlined below will make the process straightforward. Standard Parts Overview The Standard Parts Management System in Mold Wizard is a library of the most commonly used components and a system to install and adjust them. Standard parts are mold components that are installed and configured with the Standard Parts Management System. You can customize your Standard Parts libraries to match your company's design standards and expand the library to include any component or assembly.

Standard Parts Icon Ejector Pin Overview and Usage The Ejector Pin function alters the length of ejector pins that were created using the Standard Parts function and sets the fit distance (the length of the tight fitting ejector-pin hole). The Ejector Pin function uses the parting sheets used in forming the cavity and core (or regions extracted from the finished cavity and core), so the cavity must be created before using the Ejector Pin function. When ejector pins are created in the standard parts process, you must select a pin that is longer than necessary so it can be adjusted to the correct length.

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Slider and Lifter Overview When you're constructing a mold for plastic products, sometimes undercut areas need to be formed by sliders or lifters. The Slider Lifter function provides an easy way to design the sliders and lifters you need.

Slider Lifter Icon From the structure point of view, sliders and lifters are mainly composed of two parts, the head and body. The head is dependent on the product shape. The body is composed of customizable standard parts. Sub-Insert Overview Sub-inserts are used in areas on the core or cavity where intensive wear and tear occurs. They are also used to simplify the manufacture of the core/cavity. A complete sub-insert assembly comprises a subinsert head and sub-insert foot/body.

Sub-Insert Icon You should create the core and cavity before the sub-insert assembly. A sub-insert assembly can have zero or multiple sub-insert foot/bodies. When creating a sub-insert, create an envelope to enclose the volume within the core/cavity to be replaced by the sub-insert head. Gate Overview Plastic molds have flow pathways that direct the plastic to the mold cavities. The design of these pathways varies depending upon the part shape, size, and number of parts to be molded. The most common type of pathway is called a cold runner. Cold runner systems have three types of channels. Channel Sprue Runner Gate Function This is the path from the outside of the mold to the parting surface. A standard sprue bushing usually forms this section. This is the channel that is cut into the parting surface of a cavity or core or both. It begins at the end of the sprue and provides a pathway to the fill location of the mold cavity. This is the final pathway from the runner to the cavity. Gates come in a variety of designs depending upon the modling characteristics and cosmetic requirements of the molded product.

A. B. C. D.

Product Sprue Gate Runner

Sprue, Runner, Gate, and Product

Mold Wizard provides tools to design sprues, runners, and gates. You can choose gate types from the gate library. You also can customize your own gate type. The gate point sub-function enables you to easily indicate the gate point.

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Gate Icon The gates are fully associative with their pockets. When you change the gate's size or position, the pocket will change with it. When you remove a gate, the pocket is deleted. Gate Concepts Layout Type Mold cavity layouts contain single or multiple products, and single or multiple cavities. The following figure illustrates the difference between a two-cavity balanced layout and a two-cavity unbalanced layout. For the purpose of gating, the difference is that the same gate size and location can be used in both the cavities in the balanced layout. However, the unbalanced layout requires unique gates for each cavity.

A. Balanced B. Unbalanced Balanced and Unbalanced Cavity Layout Gate Position (Core or Cavity) You can position gates in the cavity or core, as shown in the following figure. The Position setting determines the orientation of the resulting gate model.

A. Cavity Side Gate B. Core Side Gate Cavity and Core Gating Runner Overview Runners are channels through which plastic flows from the sprue to the gates to fill a mold cavity.

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Runner Icon Runners are designed by defining: • • A path for the runner to follow A cross-section shape for the channel along the path

The size and shape of the section may change at various points along the runner channel. The Runner function provides tools for creating and editing paths and cross sections of runners. The runner channels are created by sweeping the cross section along the guide strings. The channels are created in a single part file and are subtracted from the core and cavity after the design is confirmed. Runners are fully associative with their pockets. When you change the size or position, the pocket changes with it and when you remove a runner, the pocket is deleted. A change to the runner crosssection shape deletes the pocket. Runner Design Process The runner design process has three design steps: 1. Guide string design 2. Projection onto parting surfaces 3. Creation of runner channels Guide String Design You can design runner guide strings in three ways depending upon the complexity of the runner channel, parting surface, and requirements for parametric adjustment: • • • Import sketch pattern Create curves in pre-defined shapes Add or remove curves from guide strings

Import Sketch Pattern The import sketch pattern method uses predefined parametric sketch patterns to define adjustable runner guide patterns. You select sketch patterns from the pull-down menu and import them to the runner component by clicking OK or Apply. User-defined runner patterns may be added to the pull-down menu by creating a sketch model, a supporting spreadsheet, and a bitmap image and adding their paths to the sketch pattern register file. Create Curves in Predefined Shapes To create curves in predefined shapes, pick the Curves through Points icon. Then pick the Point Subfunction button which displays the Point Constructor dialog prompting you to select two points. After defining the points, you can create curves in predefined shapes. If you have selected a curve and it is highlighted, you can reposition it, delete it, or increase the length of a line. Add/Remove Curves from Guide Strings To add or remove guide strings, pick the Add/Remove Curves From Strings icon. • • To add existing curves to guide strings, click MB1. To remove curves from guide strings, press Shift+MB1.

Projection Onto Parting Surfaces The Projection onto Parting Surface dialog contains the following options and buttons.

Option/Button Selection Steps Copy Method

Description Select curves and then select the parting surfaces. Move creates projected curves and the originals are deleted. Copy leaves the original curves and creates projected curves that are not associated to

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the originals. Associate leaves the original curves and creates projected curves that are associated to the original curves or the selected parting surfaces. Create Runner Channel Mold Wizard automatically finds all the guide strings in the work part and creates a swept runner channel along each guide string using the chosen cross section, its parameters, and other options. When you select an existing runner channel, Mold Wizard retrieves the selected channel data and displays it for modification. Cooling Overview The cooling function provides cooling channels in a mold assembly.

Cooling Icon Two methods are used to create cooling channels: • Channel design method (designing and creating cooling channels) • Standard Parts method The Standard Parts method is the preferred method for creating cooling channels. The channel design method is provided as an alternative method. Standard Parts Method Cooling channel models can be imported from the cooling part library, and configured by the Standard Parts Management system. This allows you to use a Standard Parts approach for the creation of cooling channels. The added benefit of using a standard part as a cooling channel is that sub-components may be attached with detailed features. The Standard Parts Library contains a catalog named Cooling. This cooling catalog contains a variety of cooling components. Channel Design Method You use the Cooling tools to interactively create cooling channels in a mold assembly. Associativity between channels and the inlet face can be achieved using predefined methods provided by the module. In addition, the module provides methods to edit and delete the guide lines or the channels. Cooling Channel Design Steps You can choose from two Channel Design Steps in the Cooling Channel Design dialog: • Define Guide Path • Generate Cooling Channel Electrode Overview EDM (Electro Discharge Machining) is used to produce mold cavity features that are impractical or impossible to machine with milling cutters.

Electrode Icon There are two methods for creating electrodes: • • Insert Standard Part Insert Electrode (designing and creating an electrode)

The standard part method is the preferred method for creating an electrode. The user design and creation of electrodes (Insert Electrode) is provided as an alternative method. Electrode Standard Part Method You can use the Standard Parts approach for creation of workpieces, sub-inserts, and electrodes. The added benefit of using a standard part is that subcomponents may be attached and pocket-cutting bodies may be included with detailed features.

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The Standard Parts library contains a catalog named ELECTRODE. This electrode catalog contains a cavity and core electrode. Positioning The position of the electrodes are parametrically controlled relative to the Product Model Mold Coordinate system, MCSYS. If you set the MCSYS to the center of the product model, the position of the insert will also be positioned relative to the center of the product. Standard Parts as Electrodes are similar to Standard Parts as Sub-Inserts and Workpiece. The electrode parts contain a drawing with dimensions to the electrode body originating from the MCSYS. The cavity or core shape is applied to the electrode though use of the mold-trim function. Electrode Design Process The process for designing electrodes is: 1. 2. 3. 4. 5. Create Envelope Create Head Create Coordinate system Create Foot Create Drawing

Mold Trim Overview The Mold Trim function automates the process of associatively trimming sub-inserts, electrodes, and Standard Parts such as slides, lifters, and core-pins, to the form of the cavity or core. The Mold Trim function is designed to trim child components of the prod node. If the project is a family mold, components selected for trimming will be trimmed to the form of the active family member.

Mold Trim Icon Trim Side The Mold Trim function may be used to trim a component to the form of the cavity or core. The Trim Side option determines whether the component will be trimmed to the cavity or core form. The Cavity-Side Surface option determines that the target component will be trimmed to the cavity form. The Core-Side Surface option determines that the target component will be trimmed to the core form. Trim Surface The Mold Trim function uses sewn sets of surfaces or regions to trim the components. By default, the same surfaces used to trim the cavity and core blocks will be used. In some cases (such as when the Solid Patch function is used to complete the parting design), the surfaces of the cavity and core include simplifications created by the solid patch. If a Mold Trim operation is needed for a component that would be trimmed by an area of the parting sheet that involved a solid patch, use the Mold Surface option. The Trim Surface provides two methods for trimming surfaces: • • Parting Surface Mold Surface

Parting Surface The Parting Surface method uses the parting sheet sets found in the parting component to trim the target component. These are the same sheets that were copied to trim the cavity and core bodies.

Mold Surface The Mold Surface option is used when the parting sheets that formed the cavity and core are not suitable to trim the target component. In this method, a region is extracted from the cavity and core bodies into the parting part, and this region is used for Mold Surface trimming of the target component.

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Create Pockets Overview After you have finished selection and placement of standard parts and other components, you can use the Create Pockets function to cut the associated or non-associated pockets. The concept for creating pockets is that the false body of a standard part is linked to the target body part and is subtracted from the target body.

Create Pockets Icon Pocket Clearance Pocket clearance depends on the insert group/standard part's false body. • • • You can change the clearance when you add or edit an insert group/standard part. You can use the clearance management function to assign or edit the clearance of an insert group/standard part after cutting the pocket. Some offset features are created to reflect the clearance. When you reposition or resize an insert group/standard part, the pocket moves or changes along with the standard part. (The pocket is associated with the part.) This functionality occurs when the Break Association option is toggled off.

When to Create Pockets To minimize the number of features while designing, create pockets at the last stage of mold design: • • After you cut pockets, the number of features in the assembly dramatically increases, which can affect system performance. Some updates may fail if the insert groups/standard parts are outside of the target body.

Creating Pockets Perform the following steps to create a pocket: 1. Select the target object (Design Steps, Target Bodies). 2. Select the tool object (Design Steps, Tool Bodies). 3.Highlight the target and tool objects. If you don't select target or tool objects in the first or second bodies, Mold Wizard will automatically search for them. 4.To preview the cutting pocket, toggle on the Show Target and Tool Bodies Only option. 5.Click Apply to cut the pocket. Bill of Materials Overview Mold Wizard includes a fully associative Bill of Materials (BOM) with the catalog ordering information. The parts list functionality is in the Drafting application.

Bill of Material Icon Drafting Parts List The parts list can be directly edited in the top assembly file of the mold assembly. To edit the part list field layout, open the "top" mold assembly file and start the Drafting application. The parts list layout is on drawing sheet SH1. The parts list layout can be edited by double-clicking on any field name or the plus sign at the origin corner. All parts that are in the mold assembly are listed in the moldbase parts list. The data is taken from the parts list data specified in the applicable components. However, moldbases, such as the standard (noninterchangeable) moldbases list only the moldbase and not the standard components that are installed in the moldbase by default. Assembly Drawing Overview

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The Assembly Drawing function automates the creation and management of mold drawings. You can create drawings, import predefined border patterns to the drawing, and create views. You can also hide components in each view and create balloons for components in each view.

Assembly Drawing Icon

Assembly Drawing Creation Overview The following steps are used to create a mold assembly drawing in Mold Wizard: 1. Drawing - Specify the drawing sheet name, units, and template, and create the drawing. 2. Visibility - Set the visibility attributes for the components in the assembly. 3. View - Create the views and control the visibility of the components in each view. Drawing Mold Wizard supports the creation of two types of drawings: • • Self Contained - Drawing is created in the top part of the assembly. Master Model - Drawing is created in a separate part file with the top part added as a component to this master model part file.

New Master Model File When you pick the file icon, a file selection dialog is displayed. You specify the location, units and filename of the new master model part file and click OK. The full path name of the file is shown in the Create/Edit Mold Drawing dialog. The dialog shows the default drawing name and drawing template. You can either select these default values or change them according to your needs. When you pick Apply, the master model part file with the given file name and units is created at the given location. The drawing is created in this part file and the selected template is imported. The name of the drawing sheet is specified in the dialog. Open Master Model File When you pick the folder icon, a file selection dialog is displayed to select an existing part. You select an existing master model part and click OK in the file selection dialog. If the selected part is not a master model part of the current Mold Wizard project, the software displays an error message and you are prompted to select the master model part file again. If a valid master model part file is selected, the file is opened as a displayed part. All the drawings in the master model part file are listed in the Drawings pull-down menu. If you would like to create a new drawing in this master model part file, select the Create New option in the Drawings pull-down menu. A default drawing sheet name and drawing template are shown in the Create/Edit Mold Drawing dialog. You can either accept the default values or change the values. When you click Apply, a drawing is created and the selected template is imported. The name of the drawing sheet is the name that was specified in the dialog. Creation of Section Views In Templates You can also use the drawing templates to create section views. Mold Wizard software has to identify that a particular view in the drawing template is a section view. To do this, perform the following steps: 1. 2. 3. 4. Create a view at the desired location in the drawing template. Name the view. Save the template. Repeat steps 1 and 2 for all the drawing templates in which you would like to have a section view. In the Mold Wizard preferences file (mold_defaults.def), specify all the section views in all the drawing templates under the variable MW_Drawing_SectionViewNames. The values must be separated by commas.

Now, when you create mold drawing using the template, Mold Wizard identifies the section views. In a Drawing

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To create the section views in a drawing: 1. In the Create Edit dialog, View tab, highlight the section view name from the list. 2. Set the visibility controls. 3. Click Apply. The Section Line Creation dialog is displayed. Section Line Creation The Section Line Creation dialog has three steps: 1. Select parent view 2. Define hinge line 3. Define Section line Edit Drawing Pick the Drawing tab. Choose the desired drawing sheet name from the Drawings pull-down menu. When you choose the drawing sheet from the pull-down menu, the corresponding drawing is opened and is the current drawing. You can delete the drawing by picking the Delete Drawing button. You can choose the different tabs to edit the corresponding values. Follow the same steps used in creating the drawing. Edit Section Views You can edit the section line for the section views. From the View tab, select the section view and double-click the view or click Apply. The dialog for editing the section line is displayed. To use Add Segment, select a position by using Point Constructor. A segment is added at the selected position. To use Delete Segment, select a segment. The corresponding segment is deleted. To use Move Segment, select a segment and then choose Point Constructor to specify the new position. The selected segment is moved to the new position. Pick OK to update the view. Component Drawing Overview The Component Drawing function automates the creation and management of drawings for components in the mold assembly. You can create drawings, import predefined border patterns to the drawing, and create views for each component in the assembly.

Component Drawing Icon Component Drawing Creation Overview The following steps are used to create a mold component drawing in Mold Wizard: 1. Select Components - Select the components that need drawings 2. Manage Drawing - Select drawing name, template, and views 3. Create Drawing - Create, edit, or open drawings for the selected components Select Components You select the components that are used to create and manage the component drawings. Pick the Select Components selection step at the top of the Component Drawing dialog. The Component Drawing dialog lists all the components in the assembly. You can select one or more components from the list or pick components from the Unigraphics NX graphics area.

Manage Drawing Use the Manage Drawing function to create, edit, and open drawings you have selected. Pick the Manage Drawing selection step at the top of the Component Drawing dialog. Create, Edit, Open Drawing

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You use the Manage Drawing selection step in the Component Drawing dialog to create, edit, and open drawings. Creating a Drawing Perform the following to create a component drawing: 1. Pick the component from the Component Names pull-down menu. 2. Choose the master model file or Self Contained from the Drawing File pull-down menu. 3. Choose Create New from the Drawing Names pull-down menu. 4. Enter a drawing name in the New Drawing Name field. 5. Pick a template from the Template Names pull-down menu. 6. Pick the views from the Views list. 7. Pick the Create button. The display changes to the drawing with the drawing features you selected. Edit Drawing 1. 2. 3. 4. 5. Pick the component from the Component Names pull-down menu. Choose the master model file or Self Contained from the Drawing File pull-down menu. Choose the drawing name from the Drawing Names pull-down menu. Pick the new template from the Template Names pull-down menu. Pick the Edit button. Mold Wizard edits the drawing to use the new template. The size of the drawing is modified according to the new template. The views are adjusted to the new position. The display is set to the selected drawing.

Open Drawing 1. 2. 3. 4. Pick the component from the Component Names pull-down menu. Choose the master model file or Self Contained from the Drawing File pull-down menu. Choose the drawing name from the Drawing Names pull-down menu. Pick the Open button. The selected drawing is opened.

Hole Report Overview The Hole Report function lets you create a report for all the holes in a component. The report is created from the Drafting application and is based on Drafting tabular notes. The report produced contains: • Holes placed into different categories based on hole diameter and hole type. • Hole categories arranged in increasing order of hole diameter. • Holes in each category arranged in increasing order of distance from the datum. • Hole category ID, hole diameter, hole type, and depth of hole for each category. You can customize the display of these attributes. • Unique hole ID and coordinates displayed for each hole in each category. Hole Report Icon

Hole Report Toolbar When you pick the Hole Report icon in the Mold Wizard toolbar, the Hole Report toolbar is displayed.

Hole Report Toolbar The Hole Report toolbar contains the following icons/functions: • • • • Create Hole Report - This creates the hole report. Auto Create Notes - This automatically creates notes for the holes. Edit Hole Description - This edits/sets the description of the holes in each category. Hole Report Preferences - This sets the hole report preferences.

MOLD EXERCISE
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1. BUSINESS CARD TRAY

1. Loading a Product and Project Initialization: A Product is loaded by selecting the Load Product icon from the tool bar. This will open the open part file window. Select the product part file from the open part file dialogue. Open the product part file named mdp_tray.prt. the part file will load and the project initialize dialogue will display. There set the unit to millimeter, in set the project path name choose the location where you want to save the entire part and assembly and ok.. Examine the part and review the initial assembly structure. 2. Define the Mold coordinate system: A mold coordinate system must be defined with respect to the part being molded. The principle xc-yc plane of the mold CSYS will define where the fixed and moving plates meet. The positive zc axis will define the direction in which the molded part will be ejected from the mold. Select WCS icon rotate select or verify that the first line zc axis xc-yc highlighted and the angle field is set to 90 deg and ok. The yc axis should now align with the part length and xc axis width of the part. Select the mold CSYS icon to open and adopt the current wcs to Mold CSYS. Select ok. 3. Assign a shrinkage value: Mold cavities and cores must be sized to allow for material shrinkage. Mold wizard addresses shrinkage by generating an enlarged version of the original product model called a shrink part. This is the part that used to define the mold cavities and cores. Select the shrinkage icon to open. Give the scale value as 1.005 in uniform scale field and ok. Save your work without closing your part. 4. Define the work piece or mold insert: Mold inserts are removable parts of the mold assembly that contain the surfaces that form the plastic part. The term insert and work piece are same. The work piece or mold insert is a volume of material that is slightly larger than the size of the containment volume of the part to be molded. The cavity and core portions of the mold are formed from this volume of material. Choose the work piece icon; this will open the work piece dimensions dialogue and make mdp_tray_parting

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as work part. Edit the Z down and Z up values to match the intended mold base. Z-down = 27.0, Z-up = 56.0. Choose ok to accept the remaining defaults. Fit the view. 5. Defining the layout: Layout used to center the part to the mold and to make multi impressions. Choose the Layout icon, the cavity layout dialog appears and the work part changes to mdp_tray_layout. Choose auto center, cancel the cavity layout dialogue, fit the view. Save the file without closing the part by file, save all. 6. Patching the holes using mold tools option: Mold tools icon is used to solid split a work piece for slide action or sub insert geometry, solid patch voids within the product model, cavity or core. Sheet patch complex holes or other open surface areas to create shut off geometry within the mold. The tray mold used in this exercise is simple and we use Auto patch option offered from Parting itself. If you are using mold tools for this tray we can use surface patch option to patch holes. 7. Making core and cavity by parting icon: Function of this icon is to develop core and cavity from the work piece we defined already. There are four principal functions of parting option. Parting Lines: Defines the parting line and patch regions. Parting Surfaces: Create parting surfaces. Extract Regions: Extract the cavity and core surface regions. Cavity-core: Create the cavity and core block. a. Define the parting line and patching: Select the parting function icon to open. Set or verify Auto process to off (unchecked). Select parting lines; the parting line dialogue will open. Select search parting line; search parting line dialogue will open. Select apply. Mold wizard identifies and highlights the parting lines. The product design adviser and Auto patch buttons are now available. Parting line edge is highlighted. Set the display mode to shaded. Select auto patch; two things will occur; the patch loop selection dialogue will open, with the cavity side highlighted by default. The top edge of both slot openings will highlight to indicate two patch regions. Select auto patch; mold wizard will create patch sheet bodies to cover both slots. Select back to return to the search parting lines dialogue. Select ok to accept the parting loop previously identified and highlighted by mold wizard. The system will display the parting loop and the parting lines dialogue will reopen. Select ok again to complete the parting line definition. The parting loop will change from green to magenta to indicate it has been identified. The parting function dialogue will display. If the Auto process option was turned on in the parting functions dialogue, the system would have automatically advanced to the next step in the process; create parting surface. b. Create parting surfaces: This step will create the surfaces from the parting line that will later divide the work piece into its cavity and core components. Select parting surfaces; the create parting surfaces dialog will open. Select create parting surfaces; The warning of “transition objects not defined do you want to create a single parting surface?” will come. Select ok to create a single parting surface. The system will generate a parting surface and return to the parting functions dialog. Fit the view and examine the results. c. Extract the cavity and the core region: In this step the faces that will be used to form a cavity and core will be identified and accepted. Select Extract region; the extract region dialog will open. Now the face count in the extract region dialog shows total faces of 151, cavity faces 94, core faces 57. Set the display mode to shaded and drag the slider bar of core and cavity fully to select all cavity and core faces they highlight in the display. Select ok to accept. Mold wizard will then extract the core and cavity faces and again open the parting functions dialog. d. Create the cavity and core block: In this step the parting surface sheet body, the two patch sheet bodies, and the extracted face regions of the product model will be used to create the cavity and core blocks. Select cavity-core option in the parting function dialog. The cavity and core dialog will open. Select create cavity. The select sheet dialog will appear. And the parting surface and extracted cavity face regions will be highlighted. Choose ok in select sheet dialog. The system will use the parting surface sheet body,

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the two patch sheet bodies and the extracted cavity face regions of the product model to create a cavity block. Now the view parting result dialog will come. Examine the mdp_tray_cavity.prt that it is suitable for manufacturing or not. Then ok to return to the cavity core dialog. Select create core. Again the select sheets dialog will appear this time the parting surface and the extracted core face regions will be highlighted. Choose ok. The system will use the parting surface sheet body, the two patch sheet bodies and the extracted core face regions of the product model to create a core block. Examine the mdp_tray_core.prt for manufacturing and give ok. Using these four steps in parting icon core and cavity for the tray component is created. To check the core cavity in assembly go to mdp_tray_top file and double click the file to make it work part. Using assemblies explode create explosion and edit explosion you can explode the core and cavity. Choose file – save all. 8. Adding a mold base: Mold wizard includes spreadsheet driven mold base and standard part libraries that are used to add a mold base and standard parts to the mold assembly. These libraries can be customized and expanded to fit the needs of the user. For this tray we will use HASCO_E catalog. Use zoom in/out to adjust the display. Select the mold base icon. Select HASCO_E from the catalog pull down menu. A mold base index size of 190 x 246 has been preselected. Select ok. Mold wizard will generate components of a mold. This process may take few minutes. After mold wizard is finished fit the view. Edit the mold base assembly to fit the work piece. Change the view to front view. We have to edit the size of the mold base. 9. Adding standard parts and editing mold base size: Select the standard parts icon to open the standard part management dialog. Select HASCO_E from the catalog pull down menu. The dialog will display a family of default HASCO_E plate sizes and values. In the graphics area move the curser until the upper plate highlights and the status line reads the solid body then click MB1 to select the upper plate. The dialog will update to display parameters relevant to the K20 or K251 upper plate. This project will use default K20 plate. Use the pull down menu to edit the plate_h = field to 56. Select apply. Fit the view. The mold assembly will update the display an upper plate that matches the work piece height. Similarly in the graphics area, move the cursor until the lower plate highlights and the status line reads solid body then click MB1 to select lower plate. The dialog will update to display parameters relevant to the K20 or K251 upper plate. This project will use default K20 plate. Set the thickness of the lower plate to 27. Remaining is set as default. Select ok. The mold assembly will update and now match the size of the work piece. Cancel the standard part management dialog. Select file save all. a. Add a standard locating Ring. Change the view to trimetric view. Select the standard parts icon. Select HASCO from the catalog pull down menu (not HASCO_E). From the HASCO standard parts list, select the part identified as K100A. K100A is for locating ring. Select ok.. Locating will be added to the mold assembly. Cancel the standard part management dialog. Select file – save all. b. Add a standard ejector pin. A complete mold assembly normally include many ejector pins. In this introductory activity only one ejector pin is going to be added. Choose the standard parts icon. Standard part management dialog will open. Change the classification field to Ejector pins. Select the Z41 pin from the list, choose ok to accept default values. The view is automatically changed to a top orientation and the point constructor dialog will display to aid in locating the ejector pin. Choose the arc ellipse sphere center icon. In the graphic screen select the left arc edge of the lower slot. This is only initial or rough placement. The pin location will be adjusted in the next step. Cancel the point constructor dialog. The standard part management dialog will display. Cancel the standard part management dialog. c. To precisely locate the ejector pin. Zoom in to observe the current location of the ejector pin. The pin needs to be moved down 4.5 mm. Select the standard part icon. Select the added ejector pin. The ejector pin dimensions will appear. In the standard part management dialog select the reposition part button. The reposition dialog will open. Enter –4.5 in the Y field and select ok. The Ejector pin will move to the correct location and the standard part management dialog will reopen. Cancel the standard part

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management dialog. Go to Trimetric view and partially shade the view. Standard part bodies have their partially shaded attribute set to yes. This enables you to easily visualize the standard parts placements relative to the wire frame mold base assembly. Examine the ejector pin which was not trimmed. 10. Trim the Ejector pin: Mold wizard automatically positioned the pin on the moving ejector plate. The length of the pin will now be trimmed to the correct length. Select the ejector pin icon. The Ejector pin post processing dialog will display. Accept the default settings. Select the ejector pin in the graphics window. Choose ok in the Ejector pin post processing dialog. The pin is trimmed to match the core insert face. 11. Create pockets for the Ejector pin: The created ejector pin is not pocketed from the mold base. To pocket the standard parts or solid block from mold base pocket option is used. This will subtract the tool body from the target body and it will maintain the tool body also. Choose the create pocket icon, the create pocket dialog will display. Select or verify the part option is on, Select the ejector pin in the graphics window. Select apply in the graphics window. Pockets have been created in both mold plates that intersect with the ejector pin solid. To pocket the ejector pin in the core insert, select the core insert as target body and ejector pin as tool body and apply. Ejector pin will be pocketed from core insert also. After completing the pockets then choose file – save all and close. This completes the first Exercise. In this first exercise the following fundamental mold wizard design process has been used. Loading a product and Initializing a product. Defining a Mold Coordinate System. Assigning a shrink factor Defining work piece dimensions. Defining a Mold Layout. Defining parting lines and patching shut off areas. Creating a parting sheet. Identifying and extracting core and cavity faces. Creating a Core and cavity mold insert. Adding and modifying a standard mold base. Selecting and adding standard parts. Creating pockets for the installation of standard parts. 2. CHANGING PRODUCT DEFAULT FOR MOUSE 1. Loading the product: Select the mdp_mcu.prt file. Change the unit to millimeter. Set the project path name where you want to save the assembly. In the project name window type mouse. Select ok. 2. Examine the project structure that was just created. Open the assembly navigator. Expand nodes mouse_layout and mouse_mdp_mcu_prod and observe the names used. Choose assembly – reports – list components. Information window will open and displays part name, reference set name, component name, count, comment, units, directory. The mdp_mcu part only is in empty reference set, it is a read only part. It is in inch unit. All other parts are in mm. All components are positioned as absolute only. Dismiss the assembly navigator and information window. 3. Setting Mold CSYS: Select the mold CSYS icon to open. Lock buttons allow the repositioning of the mold CSYS while remaining locked to one of the three principal planes. Selecting current WCS will set the Mold CSYS to match the orientation of the WCS. Selecting the product body center will set the Mold CSYS at the centre of the product body. Selecting boundary face center will set the Mold CSYS at the center of the selected face. Cancel the dialog.

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Determine where the parting should be placed. Orient view to Front. The orientation of the WCS for the part is correct but the Z level of the origin is not convenient for the molding. If the mold is split at the XC-YC plane of the product, there will be large steps in the parting level between mold plates and part cavities. In this part we decided to locate the WCS in the same plane as the apparently flat section shown at right side of the part. This plane is 12.7 mm above the current location of the WCS. To move the WCS to the desired parting, Choose WCS – origin. If necessary reset the point constructor to zero in all three input field. Key in 12.7 in the ZC input field. Choose ok. Now the WCS will be relocated. Cancel the point constructor dialog. To set the Mold CSYS select Mold CSYS icon and adopt current WCS as the Mold CSYS. Select or verify the current WCS is toggled on and select ok. The mouse_mdp_mcu_prod sub assembly will be translated 12.7 mm downwards (along ZC-) in the mouse_layout structure. 4. Assigning a Shrinkage value: Select shrinkage icon. In the three types of scale value select uniform scale this will apply the scale value uniformly in all directions. Type the scale factor as 1.005. then ok the dialog. Choose file – save all and close. 3. CREATING USER DEFINED WORK PIECE FOR HUB 1. Loading the part, setting Mold CSYS, assigning Shrinkage value: Load the mdp_hub.prt file and initialize the unit as default inch, set the project path name where you want, in project name field use default name, use default Mold CSYS, and shrinkage scale factor as 1.005. 2. Create a body suitable for a user defined work piece: In the window popup menu select the mdp_hub_parting and fit the view if necessary. Make layer 2 as the work layer. Choose application – modeling. Choose insert – form feature – cylinder. Choose diameter and height. In the vector constructor choose ZC axis and then ok. Enter diameter as 3.5 and height as 2.0 and select ok. In the point constructor choose reset to clear previous input, enter ZC –0.75 (notice the negative value) then choose ok. Choose create. A cylinder will appear completely encompassing the volume of the product model. Cancel from the vector constructor. 3. Identifying the cylinder as work piece:

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Choose the Work piece icon. Choose the option cavity_core. Select and confirm if necessary the cylindrical body you just created. If the work piece you created in the layer 2 is not shown go to format – layer settings – select layer 2 and click selectable button. And ok. Now it will be visible with standard block. Select and confirm the cylindrical body you just created. Choose ok in the work piece dialog. Mold wizard has identified the body you selected as work piece. 4. Defining parting lines: Make layer 1 as work layer and layer 2 as invisible. This will remove the work piece cylinder from the display. Choose parting icon. Set/verify auto process to off (unchecked). Select parting lines, the parting lines dialog will open. Select search parting lines, the search parting lines dialog will open and the body will be highlighted with a vector arrow pointing up. Choose apply, the external parting loop will highlight. To auto patch the interior hole: Set the display mode to shaded. Choose auto patch. The patch loop selections dialog will open and the internal parting loop will highlight. Select auto patch again. A sheet body will be created to patch the interior loop. Select back. The search parting lines dialog will appear. Select ok in the search parting lines dialog. The parting line dialog will open and the exterior parting loop will be displayed in green. Select ok in the parting lines dialog to accept the displayed parting loop. The parting functions dialog will open and the parting loop will change from green to magenta. This color change is a visual hint that the suggested parting loop has been accepted as the parting line. Create a parting sheet: In the parting functions dialog enable auto process. Choose parting surfaces. The create parting surfaces dialog will open. Select create parting surfaces. The warning dialog will open and choose ok in that dialog to create a single parting surface. The auto process feature will cause the extract region dialog to open. Fit the view if the entire parting region is not visible. Identifying core and cavity faces: In the extract region dialog drag and select all the cavity and core faces and choose ok. The auto process feature will cause the cavity and core dialog to open. Create tooling inserts: In the cavity and core dialog choose create cavity. A select sheet dialog will open. Select ok in the select sheet dialog. The cavity insert will be temporarily displayed. Notice that the cylindrical work piece was used in place of the default rectangular block. Choose ok to continue. The display returns to the parting part and the core and cavity dialog will reappear. In the core and cavity dialog, choose create core. A select sheet dialog will open. Select ok in the select sheet dialog. The core insert is temporarily displayed. Select ok. To save your work choose file – close – save all and close. In this lesson you, Initialize new mold projects and reviewed the mold wizard assembly structure. Set the mold coordinate system. Reviewed the scale function used for shrinkage factor. Created a user defined work piece and corresponding mold inserts. 4. FAMILY MOLD FOR TOY 1. Create a new toys project: Load the first part mdp_cir.prt. Use default inch unit. Set the project path. Project name as toys. 2. Load a second part: Open the assembly navigator. Use the expand all icon or tools – assembly navigator – expand all. Choose load product icon again and load the mdp_sqar.prt file. And accept. The assembly navigator will display new components as parts for the sqar shape are created inside your existing toys project tooling structure under the toys_layout node. 3. Create an insert for the currently active part: Close the assembly navigator, or move it out of your way. Now the two products are positioned at the same coordinates. We can position the products most effectively if we creates inserts for each, then line up the edges of the inserts. Choose shrinkage icon. The work part changes to toys_mdp_sqar_shrink. The most recently loaded product is the active part upon which many mold wizard functions operate. After you create an insert for the square you will shift focus back to the circle. Enter a shrink value of 1.005 then choose ok. Choose

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the work piece icon. Adjust the default Z value in the work piece dimension as Z_down = 0.875, Z_up = 1.125. Choose ok.

4. Create an insert for the circle part: Choose the family mold icon. The select plastic product dialog appears. Each product in the top assembly will appear in the selection list. Double click on mdp_cir. Choose the shrinkage icon. The work part changes to toys_mdp_cir_shrink. The circle is now the active product. Enter a shrink value of 1.005 and choose ok. Choose the work piece icon. Again adjust the work piece dimensions. Z_down = 0.875. Z_up = 1.125. Choose ok. 5. Position the circle and square inserts: Choose the layout icon. The cavity layout dialog appears. Use auto centre to position the entire layout at the mold centre. Choose the transform button in the cavity layout dialog. The translate dialog will appear. Move the sliders, enter values, or use from point to point to reposition the insert. Choose ok after the inserts are positioned. 6. Load the remaining toy shape products: Repeat the preceding steps to load and position the star and hex parts. Apply shrinkage values. Make certain all four product inserts are the same size. After all the inserts are positioned, choose the layout icon to open the cavity layout dialog. Choose auto center. All the four work pieces will be centered. Save the work by file – close – save all and close. 5. SOLID PATCH COMPENSATION IN THE TOOL FOR PEN CAP 1. Create a project for mdp_cap: Load the mdp_cap part in the unigraphics mold wizard with default inch unit, default mold CSYS, default project name, default workpiece, shrinkage value of 1.008 and the layout as auto centre. 2. Prepare the part for tooling design: This part has 12 windows that must be patched before we can trim core and cavity inserts. The window edges are shared between multiple faces, therefore the face cannot be patched with surface patch. Auto patch works using edge patches, but it is tedious to repeat the face confirmation process twelve times. In this case solid patch is an efficient method to use.

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Choose tools. Choose create box. Use the default value for allowance. Select the inner face containing the window openings and the small inner face near the top of the cap. Choose ok to end the selection. A block is created surrounding the material volume defined by the faces you selected. 3. Trim the patch block to the interior shape of the pen cap: Choose surface split. Select and confirm the block you just created as the solid to be split. Remove the outer material by selecting the inner face containing the windows. (The same face you used to define the patch block.) Choose trim. The enlarged sheet dialog will appear. Do not change U. Expand in the V direction to approximately by 400%, until the cone extends past both ends of the block. Choose ok to accept the UV values and trim the patch body. Cancel to return to the tools dialog.

4. Use subtract to complete the patch body: From tools in the split method section choose subtract. In the subtract option select and confirm the smaller, green patch body as target and choose the larger, cyan parting body as tool. 5. Use the patch body to create shut off faces in the windows: Choose solid patch. Select the larger parting body as target solid, and the smaller patch body as tool. Choose ok or cancel to dismiss the selection dialog. The unite operation performed by solid patch removes several faces from the core region of the parting part. These removed faces will not appear in the core tooling when it is initially created. You must plan to compensate. Mold wizard will make linked copies of the original patch body now in layer 25, in the core and cavity parts. You can use this knowledge to complete your plan to replace the removed faces. 6. Create a parting curve and face: Choose the parting icon. Enable the auto process toggle. Choose parting lines. Choose auto search parting lines. Choose apply in the search parting lines dialog. Mold wizard identify the correct parting loop. Once the parting loop has been identified, the product design adviser becomes available. Auto patch remains grayed out, an indication that solid patch successfully removed all holes from part. Choose ok in the search parting lines dialog to accept the previously identified parting loop. Choose ok in the parting line dialog. The create parting surface dialog will appear because you selected auto process. 7. Create the parting surface: Enter 8.0 in the distance window. Choose create parting surface, a warning message will appear, choose ok to create a single parting surface. Extract regions dialog will appear. Fit the

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view to see the parting face. Use the sliders to preview the core and cavity regions. The core region is truncated at the location of our patch body. Choose ok to create region features and move to the next stage of the process. The core and cavity dialog will appear. From the core and cavity dialog choose create core. The select sheets dialog will appear. Choose ok in the select sheet dialog. The view parting result dialog will appear. Choose ok in the view parting result dialog to return to the parting part. Make layer 1 as work layer and optionally make layer 27 as invisible.

8. Compensate for geometry removed by solid patch: Window to mdp_cap_core. Make layer 25 as selectable. The patch body will appear along with core block. The patch body has to be added to compensate the core of the part. Choose application modeling. Choose insert – feature operation – unite and unite the core block with the patch body. Now we got the required core block by uniting the patch body. Then save your work by file – close – save all and close. 7. PLANER PARTING FOR MDP_OUTLET 1. Loading the part and initializing: Load the mdp_outlet.prt file in the mold wizard with the inch unit, project path name as you wish to save, with the default project name, MCS, work piece. Use shrinkage scale factor of 1.008. Use layout Auto center. 2. Define the parting lines and making core and cavity: Choose the parting icon. From the parting function dialog choose parting lines then auto search parting lines. Choose apply to begin processing. Mold wizard will quickly finds and displays the natural parting edges of this simple part. Choose Auto patch. Patch loop selection dialog will appear. In patch loop dialog choose automatic and select auto patch. Then choose back to return to parting lines dialog. Choose ok in search parting line dialog. Choose ok again in the parting lines dialog to enter into a create parting surface dialog. Type 200 in the distance field and choose create parting surface. Choose ok for the warning message. Extract regions dialog will come and ok the dialog. Core and cavity dialog will come. Choose create cavity and ok the select sheet dialog will give you cavity insert. Then ok the view parting result dialog. Then choose create core in the core and cavity dialog and ok the select sheet dialog. This will give you core. Then ok the view parting result dialog. This completes core and cavity preparation. Choose save all and don’t close. 3. Creating insert for two cylindrical projections: From window choose mdp_outlet_cavity_011.prt. Choose mold tools icon. Select create box icon inside the mold tools icon. Select the lengthy cylindrical surface of the pin for which we are going to prepare separate insert. There are two pins. We have to create insert for both. Select any one first. Then after completing for one we can do the same for other. Type 35 in the allowance column and apply. This will create a box. This box should be trimmed to get the shape of the two pins. Select split solid icon inside mold tools and select the newly created box as target body and select the top face of the cylindrical projection (pin) as tool body. This will trim the box. In the trim method dialog choose flip trim. Select the bottom face of the cavity insert in the split solid dialog for tool body, apply land choose flip trim. Now we got top and bottom trimmed box for pin insert. We have to trim the box up to the big cylindrical face, which is in the bottom face of the cylindrical projection. We cannot able to trim the box by using that small cylindrical face. The surface is not large enough. To trim the box up to that face, we have to enlarge that surface at least two times. Cancel the split solid dialog. To enlarge that cylindrical face, choose edit – free form feature – enlarge. Select the larger diameter cylindrical surface of less height and enlarge the Vmax and Vmin fully and apply. Again select the newly enlarged surface and enlarge the Vmax and Vmin fully and ok. Choose split solid option from tools. Select the box as target body and select the newly enlarged bigger surface as tool body, and apply. In the enlarged sheet dialog type the maximum percentage as 1000 and drag Vmax and Vmin fully to trim the box and ok. Ok again in the trim method dialog. Now the box is trimmed to the cylindrical projection size. Still it has to be trimmed. Cancel the split solid dialog. Select the intersect icon from tools icon. Select the trimmed box as

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target body and cavity insert as tool body and check the retain tool option and ok. Now we get the required shape for the pin insert. 4. Subtracting the pin insert from cavity insert: Choose create pocket option. Select cavity insert as target body and select trimmed and intersected box as tool body by checking solid in pocket management dialog and ok. Then blank the unwanted sheet body by edit – blank – type – sheet body – select all – ok. Now the pin insert area is subtracted from cavity insert. Similarly do it for the second pin also. Choose file – save all and close. 8. NATURAL PARTING WITH ISOCLINE CURVES FOR MDP_CUP1.PRT

1. Loading the mdp_cup1.prt: In this exercise you will use isoclines to divide a blend face at the natural parting. Load the mdp_cup1.prt file in mold wizard with default inch unit, Project path and name. Use default work piece, use auto center in layout and apply shrinkage value of 1.008.

2. Set the Mold CSYS to reflect ejection off the core side of the mold:
The positive Z direction indicates the direction that the part will be ejected from the mold. To efficiently mold this part, the cup needs to be inverted inside the work piece. This will require a Mold CSYS rotated 180 degrees about the YC axis. Choose WCS – Rotate. Select +YC axis: ZC-XC and set the angle field to 180 degrees. Select ok. The positive ZC axis should now point down and away from the bottom of the cup. Choose the Mold CSYS icon, the mold CSYS dialog will open. Select the current WCS is toggled on and select ok. The display will reorient to match the new Mold CSYS. Fit the view. The XC-YC plane now lies on the flat bottom of the cup. This is not the correct parting plane. 3. Defining parting line: Choose the parting icon, the parting functions dialog will open. From parting functions dialog select parting lines, the parting lines dialog will open. From the parting lines dialog select auto search parting lines, the search parting line dialog will open. Select apply. The Mold Wizard system finds an edge. But that edge is not precisely the natural parting. The Product design adviser become available. It is a good habit to check the adviser even when you do not suspect problems. Choose product design adviser. Product design adviser dialog will open. In that choose settings. In settings choose split face. Face split dialog will open. In that check split by isocline and select the crossover face (ie the blend face near to the parting line.) and apply. It will divide the selected crossover face. Select back, product design adviser dialog will come. Back again, search parting lines dialog will come. In that choose select body, solid body selection dialog will come. In that

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select the part and apply in search parting lines dialog. This will give the corrected natural parting line. Choose ok. Ok again in parting lines dialog. Cancel the parting functions dialog. The exact parting line is some distance down from the current Mold CSYS. We should correct it. From window choose more parts in that select mdp_cup1_layout. Choose format – layer settings and choose 255 layer as selectable and apply then cancel the dialog. Choose WCS – origin. Select the isocline curve centre as origin and cancel the dialog. Choose Mold CSYS. Now the mdp_cup1_top will open. In that choose format – layer settings. Make 255 layer as selectable and apply then cancel. Choose WCS origin. Choose the isocline circle center which we got later. Now the MCS moved down to the natural parting position. Then apply in the current WCS in Mold CSYS and cancel the mold CSYS dialog. Go to the parting icon, this will open parting functions dialog. Here the MCS and parting line are in same Z position. Choose parting surface. This will open create parting surface dialog. In the create parting surface dialog choose create parting surface, ok the warning and ok in the extract region dialog. Core and cavity dialog will come. In the core and cavity dialog choose create cavity and ok the select sheet dialog and ok the view parting result dialog. This will give the cavity insert. In the cavity and core dialog select create core, ok the select sheet dialog and ok the view parting result dialog. This will give core insert. Finally save and close by file – close – save all and close.

9. SELECTING TRANSITION OBJECTS FOR MDP_CUP2

1. Loading the mdp_cup2.prt: Load the mdp_cup2.prt with default unit (inch), default name, default work piece, layout as auto center and shrinkage factor as 1.008. Set you location for the files to save. After loading the default mold CSYS choose WCS – orient. Select top flat face of the cup2. Now the WCS shows the correct cavity side but it lies on the top of the cup2. Choose WCS – origin in that choose circle center and select the extreme edge of the cup2. Now the WCS set correctly.

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2. Defining parting line: Choose the parting icon. Parting functions dialog will come. In that select parting lines. Parting lines dialog will come. In that choose auto search parting lines option apply and ok the dialog. In the parting line dialog choose auto transition objects. In that select convert transition object. It will automatically identify the transition objects and give ok in that dialog. And again ok in the parting line dialog. Create parting surface dialog will come. In that choose create parting surface icon. Parting surface dialog will come. In that surface type as bounded plane choose XC direction and enlarge the surface enough to divide insert and ok in the view trimmed sheet dialog. Choose sew surfaces in the create parting surface dialog. Choose ok in the extract region dialog. In cavity and core dialog choose create cavity and choose create core to create cavity and core respectively.

Parting surface Choose file – close – save all and close. 10. PARTING SURFACE CREATION FOR MDP_DRYER 1. Loading the mdp_dryer.prt: Load the mdp_dryer.prt with default unit (mm) and project name. After loading the part Choose WCS – rotate – rotate about +YC axis: ZC-XC and type 270 and apply. Then cancel the dialog. Choose Mold CSYS apply and cancel the dialog. Choose layout – auto center and cancel the dialog. Choose shrinkage type 1.008 in uniform scale factor and ok. Choose work piece and ok with default work piece 2. Patching works: Choose tools icon. Just click on surface patch and cancel it. This will enter into mdp_dryer_parting file. Choose application – modeling. Choose edit – free form feature – enlarge. Select the transition

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face of the dryer (ie the curved vertical flat face) and apply. This will form a sheet on the face. But we required the surface to be filled only the inner area. But it exceeds in outer also. We should trim that surface. Choose insert – free form feature – trimmed sheet. Select the newly created sheet in inner side. Select the inner edge of the vertical flat face as trim boundary. We have to select three edges. Then apply in the trimmed sheet dialog and cancel it. Choose insert – curve operation – extract – edge curve. Select the bottom edge of the newly created surface and ok. Then cancel the dialog

There is another face to be filled in the back side of the dryer part. There is a small opening face. Choose – edit – free form feature – enlarge. Select the single face that covers the transition opening and apply. Then cancel the dialog box. To trim the newly created second surface, choose insert – free form feature – trimmed sheet. Select the new sheet2 in the inner side as target sheet body. Select the three inner edges of the face which bounds the opening as trim boundary and apply. Then cancel the trimmed sheet dialog. Choose insert curve operation - extract – Edge curves. Select the bottom edge of the newly created sheet2 and ok the dialog. Then cancel the dialog. We have to convert the two new sheets as patch sheet. So choose existing surface option inside the tools option of mold wizard. Select the two new sheets and ok. Now the two sheets converted to patch sheets. 3. Parting option: Now we have to patch the inner holes and pockets. We will do it with the help of auto patch. Choose parting icon. Choose parting lines in the parting function dialog. Choose auto search parting lines in the parting lines dialog. Apply in the search parting lines dialog. Now the product design adviser and the auto patch buttons are active. Choose product design adviser in the search parting lines dialog. Check the vertical in the face button. Choose back button. Now search parting lines dialog comes again. In that choose auto patch. Patch loop selection dialog will come. Now the part shows the edges going to be patched automatically. Choose auto patch. Now all the open holes and pockets are patched automatically. Choose back in the patch loop selection dialog. Then ok the search parting lines dialog. Now the parting line is shown. But we need to avoid the transition objects. That is why we extracted the bottom edges of the two newly created sheets. But it is not showing in the display. Check the show product model in the parting line dialog. Now it shows the part and the two extracted curves. Choose edit, parting lines in the parting lines dialog. It is showing the mold wizard identified parting line, which is to be changed. Remove the transition curves in two places by pressing shift and selecting it and select the two bottom curves after releasing the shift button. Now the parting line is fully flat and there is no Z variations in the parting line. Choose ok in the edit parting line dialog. Choose ok again in parting lines dialog. Now the create parting surface dialog comes. In that choose create parting surfaces. Ok for the warning, and ok for the extract regions dialog also. Core and cavity dialog will come. Choosing create cavity, ok the select sheets dialog and ok in the view parting result dialog will give cavity insert. Choosing create core, ok the select sheets dialog and ok in the view parting result dialog will give core insert. Choose file – close – save all and close.

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MOLD ACTIVITIES

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