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Import the model called -‘TSPM2003_PSHAPE_Workshop3.psmodel’

Start PS-Moldmaker from the applications menu

Start the Cavity/Core Wizard

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Select the option to ‘Insert core/cavity plates with inserts’ and then Next

The first phase of the Cavity-Core Wizard allows the user to establish how the split surfaces are built into the tool. The ‘noninserted core/cavity plates’ option will create the split surfaces directly into the cavity core plates and when the Die Wizard is launched from here it will step through standard plate sizes.

LH_ INSERT_ DATUM

LH_ CAVI TY_ SOLI D

LH_ CORE_ SOLI D

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An insert registration page has now been added to the CCW in order to simplify the naming convention process, this is especially important when adding multiple inserts and slides. • Pick each radio button and then select the item in the graphics window associated to this selection

Once the Cavity\Core inserts and workplane are in the selection hit the register button to register the components for use with PSMM

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RH_ CAVI TY_ SOLI D RH_ I NSERT_ DATUM RH_ CORE_ SOLI D 78 .

Repeat the process for the RH insert set

Select ‘Next’

NOTE: Naming convention are still used in the background :Moldmaker Naming Conventions
SW_COREn (must be used as the solid name for the slide core) SW_WPn (must be used to determine the orientation and origin of the slide mechanism) DW_Cavity (must be used to name the Cavity Insert Solid) DW_Core (must be used to name the Core Insert) DW_WP (is the workplane associated with the Die Insert +Z orientated towards the cavity) DW_Cavity_Plate ( same as DW_Cavity but for the MPD option ) DW_Core_Plate ( same as DW_Core but for the MPD option )

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This next stage of the process allows us to pre-select a supplier for our Mold components, we now have a list of 16 supplier 2 of which are a generic layout that can be used to create custom styles. • Select the ‘Hasco’ catalogue an then ‘Next’

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The plates will now be fitted around the inserts and the size of the series (the X/Y plate dimensions) will be selected based on some configurable clearance values for the height, width and length of the plates. If these clearance values are changed then the list of plates will be re-filtered. • Set MX to 100, MY to 100 and MZ to 30

The Moldbase can be flipped by 90 degree increments.

Change the thickness of the Cavity Plate to 156 and the Core Plate thickness to 156

The Moldbase tab allows us to establish the size and thickness of the plates. If we switch to using ‘Custom’ here then the user can enter his own value for the series sizes and change the dimensions of the pillars and screws via the ‘dimensions’ buttons.

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• • • Switch the tab to Inserts/Pockets Change the radio button to position the inserts by D2 and G Set D2 to 65 and G to 0 • In this example we need to be more selective as to how we create the fillets so change the Corner Radius to ‘0’ and then hit the ‘Copy to All’ button 82 .The Insert/Pockets tab allows the user to position the pockets in relation to the plates.

83 .• Switch to the Slide tab and then select ‘Insert a Slide Mechanism’ button The first page of the Slide Wizard allows us to – create a new core via the ‘Slide Core Wizard’ register slide core solid that has been modelled manually move onto designing a slide mechanism Note – It is possible to create a slide mechanism by supplying a workplane only providing the workplane is correctly positioned. • Change the radio button to the ‘Register’ option To save time slides 1 and 2 (which form the grills on the end) have already been registered. Its Z axis must be aligned to the intended movement direction of the slide unit and its X axis must be aligned to the direction of draw.

• Change the radio button to ‘design slide mechanism’ 84 . Slides 1 and 2 have already been registered.• • • Select the workplane positioned in the centre backface of the core as shown above Next activate the select slide core solid radio button and select the slide core solid The workplane and solid can now be registered for use with Moldmaker Note.

The second page of the Slide Wizard allows us to establish the slide configuration and switch between working off different mechanisms. • • • Select ‘Slide Mechanism 1’ from the list Choose slide type ‘A’ Next 85 .

The slider required for this demonstration have been provided via a *. Copy the xml file (UsrDimensions. • When prompted choose the above slide from the list 86 .xml file.xml) provided with this document to : D:\dcam\product\PSMoldmaker5440\file\catalogs\generic_metric Note :-PoweSHAPE will need to be re-started for these settings to take effect.As soon as Stage3 of the slide wizard starts the user is prompted to select a slider from the list.

• • • Change the vertical offset to –5 Click on the image of the ‘Heel Block’ (Arrowed above). Change the ‘Heel Block Edge Height’ to 35 87 .Once the slider is selected the slide unit is previewed in the graphics window and the user change any the above parameter to suit the slide design.

• Click on the image of the ‘Angle Pin’ 88 .

The Slide travel can be calculated by defining the length of the ‘Angle Pin or the length’ of the ‘Angle Pin can be calculated by the Slide Travel’. • • • Set the Day Light to ‘300’ Set the Angle Pin length to 175 Next 89 .

• Set the ‘Length’ of the Guide Rails to 145 • • Set the ‘Width’ to 24 Set the ‘Height’ to 20 90 . basically if the angle pin is still engaged when the press has reached its maximum opening stroke then the effective height of the pin is reduced.NOTE: The Day Light parameter refers to the open distance between the slider and the cavity plate. This parameter is determined by the movement of the machine and can effect the slide travel calculation.

• Activate the ‘Insert a wear plate’ check box • Select ‘Next’ • Select Yes then‘Next’ 91 .

Select ‘Slide Mechanism 2’ from the ‘Selected Slide Core’ pull down list. • • • Select the option to ‘Copy’ dimensions Copy from ‘Slide Mechanism 1’ Then ‘Accept’ • Select ‘Yes’ when prompted 92 .• Leave the pocket set to Through.

• • Select ‘Slide Mechanism 3’ from the pull down list Next 93 .

• Select the above dimension for the slider when prompted 94 .

• Pick the Heel Block Image 95 .

• • Set the radio button to ‘Machine the Heel Block’ directly Next select the image of the ‘Angle Pin’ 96 .

• Position the ‘Angle Pin’ on the top of the insert 97 .

• • • Set the Day Light to ‘300’ Set the Slide Travel ‘15’ Next • • Set the Length of the guide rails to 75 and the width to 18 Next 98 .

• • Set the pocket to be ‘Blind’ and the Length to be ‘75’ Next 99 .

• Increase the Moldbase size to 496x796 to add strength to the back of the Heel Block 100 .

• Finally select ‘Finish’ to complete the process Creating the Moldbase 101 .

• • Deselect the ‘Support plate’ check box Reduce the ‘Riser Thickness’ 96 • Next 102 .

• Next • Finish Select the Moldbase Wizard from the assistant window Once the Moldbase has been constructed it is possible to go back into the Wizard and change the parameters (this is currently under preview). We are currently working towards making all the wizards work in this way. 103 .

• • Change the ‘Riser Thickness’ to 116 Next 104 .

• Next • Finish Workshop Example 3 Ends Here Adding Mold components 105 .

psmodel’ • Switch the ‘Fixed Half’ level group ‘off’ so only the MH components are visible Enter the component wizard 106 .Adding Ejection • Import the model called -‘TSPM2003_PSHAPE_AFTER_MB.

• Select a Z41 Ejector Pin from the HASCO Demoulding Components list • Un-ticjk trim pin • Select Dimensions 107 .

• • Select the above dimensions Create Ejector Pins are automatically locked to the Ejector Base Plate and twin views are now set up to aid the positioning of pins. 108 .

enter a distance and reselect the attachment points. 109 .0> as shown above Its worth noting that an additional toolbar has been adding for positioning the components using the ‘Bolt’ command. If you double click the component after positioning it now raises the component positioning form. This toolbar allows the user to flip the alignment. This allows the user to reposition the component after placement using either another cursor click or entering co-ordinates in the text boxes provided.• Use the intelligent cursor to position the pin a <-140.95.

95.• Double click the component and change its position to –145.35. 0 • Position a second pin at <-145.0> 110 .

• Position a third pin at <145.0> 111 .95.

35.0> • Hit the ‘ESC’ key followed by the ‘Select Component’ button 112 .• Position a fourth pin at <145.

• •

Select a Z451 Ejector Sleeve Choose the dimensions 3 (Inner Body) x 250 (Length)

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• Looking down the plan view position 4 off Ejector Sleeves to the centre of the 4 cored out bosses as shown above • Hit ‘Esc’ and then select another component • Select a ‘FlatEjectorPin’ from the Hasco catalogue 116 .

5 • Un-tick trim pin • Create 117 .2x7.• Select the dimensions 8x200x1.

• Position the blade in the approximate centre of the rib as shown above (the position import form may be useful here for positioning between 2 corners) Cancel the ‘Component Wizard’ and then start the ‘Feature Wizard’ 118 .

• • Select the ‘Ejector Trimming’ option and then ‘Create’ Quit by hitting the ‘Back’ button 119 .

Go back into the ‘Component Wizard’ • Select a Z41 Ejector Pin • Select the dimensions 3x400 120 .

Set the length of the pin to 325 Change the pin function to ‘Core Pin’ Attach to ‘Bottom clamping plate’ Set the depth to ‘10’ Un-ticjk trim pin Re-enter the Feature Wizard’ 121 .

• Select the ‘Ejector Pin Holes’ option and then ‘Create’ 122 .

The form is raised once for each different diameter. 123 .If the option to ‘always ask parameters’ is selected then the user gets the opportunity to configure the fits and clearances of all the plates that the pins are fitted through.

The user has the ability to stop the simulation at a set height. maybe to take a section view in the open position.Simulating the Mold A new simulation option has been added to MoldMaker for simulating the Mold cycle. 124 . and then adjust the position via a slider. this will open the tool to a configurable opening stroke and then send the Ejector set forward to the maximum available Ejector Stroke.

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An exploded view of the Moldbase can also be created here. • Click the ‘Done’ button to exit out of the wizard 126 .

• Blank everything except the Core Plate and Core Inserts Go back into the ‘Component Wizard’ 127 .

• Select a HASCO M16x90 .Z31 Socket Head Cap Screw 128 .

• • • Set the Component to ‘Attach to’ – Core Plate Set the counterbore depth 18 Finally select the ‘Create’ button 129 .

0> o <-25.Once the component has been created it will become attached to the cursor and wait for the user to select a plane or face to lock.0> 130 .105. it will turn yellow when the cursor is moved over it and pink when it becomes selected and locked • • Set the view to –Z Position 1 bolt in each insert as shown above approximately at – o < 25.105. • Pick the bottom face of the Core Plate.

• Activate the workplane ‘DW_WP1’ 131 .

YZ 132 . ZX.• Select the cap screw that is positioned in the LH_Core_Insert and mirror with a copy around YZ.

• Activate the workplane DW_WP • Select the cap screw that is positioned in the RH_Core_Insert and mirror with a copy around YZ.YZ 133 . ZX.

Start the ‘Feature Wizard’ 134 .

• Select ‘Screw Holes’ followed by ‘Create’ • Back 135 .

Cooling Wizard Start the Cooling Wizard’ 136 .

• • Select the ‘Moving Half’ – automatic selection radio butto Next • Set the default parameters as displayed above 137 .

• • • Make sure the principle plane is set to ‘Z’ Set the ‘Depth’ to ‘60’ Switch the grid locking button ‘On’ • Switch the line creation mode to single line 138 .

60.0 139 .• • Set the view to look down +Z Start the first cooling line at approximately –360. 60. 0 • End the first line at approximately 340.

• Switch to ‘edits’ mode • Pick the cooling channel previously created 140 .

• Make the hole a ‘through hole’ • Edit the hole properties 141 .

• Make the ‘Keep start and end the same’ check box active 142 .

• Set the principle plane to ‘Y’ • Select the ‘move plane to point’ icon and snap to the wireframe of the first channel to align the grid so it intersects 143 .

• Set the grid spacing to 15 • Using single line construction mode start the first vertical channel at 150.30 and end it at –150 0 150 144 .0.

30 and end it at – 75.0.• Create the second vertical channel at –75.150 • • Select the wireframe edits icon and then select the 2 vertical lines Goto general edits via the icon in the Cooling Wizard 145 .0.

• Create a mirrored copy around YZ • Goto ‘Edits Mode’ and box select all the vertical channels 146 .

• Change the hole diameter to ‘20’ and ‘Accept’ 147 .

• Next select the vertical hole is the Core Plate only • Change the holes to be ‘through holes’ • Next 148 .

• Edit the clearance values • Change the clearance distance to 5 149 .

• Check the circuit for collision 150 .

• • Check the influence of the circuit Deactivate the ‘Show influence’ check box 151 .

psmodel Goto <Tools – Options .Assembly Options – General> 152 .• Finally select ‘Finish’ to complete the circuit Creating Custom Components • • Open the model TSPM_Components.

153 .• • Acitvate the check box ‘This model is a component library’ Accept The above sets the model up as use as a component library the contents of which can be categorised by setting specific components up with a class or class name.

The class name for each component is set up via right clicking on the component definition or component assembly and then selecting the ‘set class name’ option. The name can be then set and accepted • • Save and Close the model Go back to the main model and under ‘preview mode’ select <File – Open Component Library> 154 .

• Select and Open the TSPM_Components library. if it doesn’t appear in the list then you may have to Browse to it Goto o o o – Tools Show Component Library Window • • Switch the class tab to ‘Hot_Runner’ 155 .

• Click on the ‘Hot_Manifold’ icon to create the component X2 • Create 2 ‘Bushing_Assemblies’ • Create 1 ‘Hot_Bush’ 156 .

• • Select the plane at the top of the hot bush and holding down the left mouse button start to move the component Holding down the ‘Ctrl’ key to anti align the component Move the cursor over the top plane attachment and then release the left mouse button 157 .Create a Plane-to-Plane relation between the Hot Bushing and Top Clamping Plate using a drag and drop approach.

158 .• Right click and edit the relation just created • Enter an distance parameter of –10 and then close the toolbar • Using a similar approach drag and drop the Hot Manifold component onto the Hot Bushing. Use the coincident plane and line attachment between the top face and centre hole of the Manifold and the coincident plane and line attachment at the top of the threaded portion of the Bushing.

• Using the coincident plane and line attachments on the top face of the Bush Assembly drag and drop the 2 sub assemblies onto the 2 holes on the bottom of the Hot Manifold 159 .

• Double click on the Hot Bushing 160 .

• Change the Y value to 10 (if the hot runner was correctly assembled then all the components will move in relation to the Hot Bushing) 161 .

• Finally right click over the Hot Manifold and then select the option to Modify Parameters (this instance) 162 .

before proceeding make sure that this has been imported into the database.psmodel’ has been included with this documentation. 163 . A template called ‘TSPM2003_Tooling_Template.• Change the HotTipLeft and HotTipRight parameters to 100 and –100 and then Accept Drafting The drafting module has recently under gone a number of improvements that include improvement to the Hidden Line algorithm and improvements to the section views.

A.• Start PS-Draft • Create a new drawing view • Right click over the view and select modify • • • Activate the template check box Select the model ‘TSPM2003_Tooling_Template’ Select the drawing ‘G.’ 164 .

• Select the schedule button from the drafting toolbar • Select the ‘Assembly’ schedule type and activate the view 165 .

• Position the schedule box as highlighted above • Create a new drawing view • Right click over the view and select modify • • Select the model ‘TSPM2003_Tooling_Template’ Select the drawing ‘Plan Views’ 166 .

• Right click over the left hand view and modify the view 167 .

• Change the view properties to be ‘Hidden’ and ‘Display Hidden Lines’ • Create a new drawing view • Right click over the view and select modify 168 .

• • Select the model ‘TSPM2003_Tooling_Template’ Select the drawing ‘Cavity Insert’ 169 .

• Create a new drawing view • Right click over the view and select modify • • Select the model ‘TSPM2003_Tooling_Template’ Select the drawing ‘Section’ 170 .

• Draw a staggered line through the left hand view using straight lines only and then convert the lines to a composite curve Take a section view • 171 .

this can be selected from the ‘Tools’ menu. 172 .• We will finish off drafting by creating an ‘assembly plate hole schedule’.

these options are under … … <Tools-Options-Drafting-Schedule> The ‘Holes to Include’ option can be set to … Normal to the View – This will only include holes that are normal to the current view direction At any angle – This will include all holes in the current selection regardless of drill direction In addition to the ‘Holes to Include’ option there is a flag that can be set to ‘Include Pre-Drilled Holes’. this holes are drilled by the manufacturer of the plate). Finished 173 . By default holes that are flagged as Pre-Drilled will be ignored by the schedule template (Pre-Drilled holes are the holes that appear on the standard component.Before creating the hole schedules its worth noting that there are some configurable options that will determine the holes and hole details that will be included in this drafting.