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UNIGRAPHICS

MOLDWIZARD DESIGN PROCESS


STUDENT MANUAL
September 2002
MT10420 - Unigraphics V18.0.3.2

EDS
Proprietary & Restricted Rights Notices

Copyright

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

2002 Electronic Data Systems Corporation. All rights reserved.

Restricted Rights Legend

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

Warranties and Liabilities

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

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

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

Trademarks

EDS, the EDS logo, UNIGRAPHICS SOLUTIONS, UNIGRAPHICS, GRIP, PARASOLID,


UG, UG/..., UG SOLUTIONS, iMAN are trademarks or registered trademarks of Electronic
Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the
property of their respective owners.
MoldWizard Design Process Student Manual Publication History:

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


Version 16.0.2.2 . . . . . . . . . . . . . . . . . . . . August 2000
Version 17.0 . . . . . . . . . . . . . . . . . . . . . . . December 2000
Version 18.0 . . . . . . . . . . . . . . . . . . . . . . . October 2001
Unigraphics NX . . . . . . . . . . . . . . . . . . . . September 2002
Table of Contents

Table of Contents

Course Overview
MoldWizard Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2
Student Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2
Student Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Lesson Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Workbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3
Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . -4
Class Standards for Unigraphics Part Files . . . . . . . . . . . . . -4
Parts Directory Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5
Staged Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -6
Spare Parts and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . -6

Introduction To MoldWizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1


What Is MoldWizard? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Introductory Lesson Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Activity 1-1: Starting Unigraphics and MoldWizard . . . . . 1-4
The MoldWizard Design Process . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Loading A Product and Project Initialization . . . . . . . . . . . . . . 1-8
Activity 1-2: Beginning a Mold Project . . . . . . . . . . . . . . . . 1-10
The MoldWizard Assembly Structure . . . . . . . . . . . . . . . . . . . . 1-14
Define the Mold Coordinate System . . . . . . . . . . . . . . . . . . . . . 1-15
Assign a Shrinkage Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Activity 1-3: Mold Csys Orientation and Shrinkage . . . . . 1-18
Define the Work Piece / Mold Insert . . . . . . . . . . . . . . . . . . . . . 1-22
Work Piece Dimensions Dialog . . . . . . . . . . . . . . . . . . . . . . . 1-23
Define the Work Piece / Cavity Layout . . . . . . . . . . . . . . . . . . . 1-24
Activity 1-4: Defining the Work Piece and Layout . . . . . . . 1-25
MoldWizard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Parting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

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Patching Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35


Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Extract Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Cavity and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Activity 1-5: Parting, Core, and Cavity Definition . . . . . . . 1-39
Adding a Moldbase and Standard Parts . . . . . . . . . . . . . . . . . . . 1-57
Mold Base Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Standard Parts Management . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Ejector Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
Create Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
Activity 1-6: Adding a Mold Base and Standard Parts . . . 1-60
Other MoldWizard Design Process Functions . . . . . . . . . . . . . . 1-80
Design Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
Activity 1-7: Design Changes and Associative Tooling . . . 1-81

Initializing A Mold Design Project . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


Load Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Proj Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Proj Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cloning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Field Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Project Assembly Members . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Product Sub Assembly Members . . . . . . . . . . . . . . . . . . . . . . 2-9
Activity 2-1: Changing Project Defaults . . . . . . . . . . . . . . . 2-11
Mold Csys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Shrinkage .......................................... 2-16
Edit Scale Dialog Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Scale Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Reference Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Scale Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Activity 2-2: Choosing and Setting a Mold Csys . . . . . . . . 2-19
Instruction Format for Initializing a Project . . . . . . . . . . . . . . . 2-22
Work Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Work Piece Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Cavity & Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Cavity Only, Core Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Work Piece Dimensioning Methods: . . . . . . . . . . . . . . . . . . . 2-26
Product Maximum Dimensions . . . . . . . . . . . . . . . . . . . . . . . 2-27
Work Piece Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

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Activity 2-3: User Defined Work Piece . . . . . . . . . . . . . . . . . 2-29


Parting Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Product Design Advisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Activity 3-1: Product Design Advisor . . . . . . . . . . . . . . . . . . 3-4
Patch Up Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Allow Non-Associative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Solid Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Planar Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Activity 3-2: Planar Patches . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Sheet Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Surface Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Edge Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Existing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Auto Hole Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Activity 3-3: Surface and Edge Patches . . . . . . . . . . . . . . . . 3-22
Create Patch Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Create Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Surface Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Solid Patch Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Solid Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Activity 3-4: Patch Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Split Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Solid Parting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Subtract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Solid Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Profile Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Activity 3-5: Solid Patch Compensation in the Tool . . . . . 3-41
Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Activity 3-6: Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Family Molds and Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Family Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Remove Family Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Load Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Load Product and Mold CSYS . . . . . . . . . . . . . . . . . . . . . . . 4-4
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Layout Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Automatic Rectangular Layouts . . . . . . . . . . . . . . . . . . . . . . 4-6

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Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9


Insert Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Reposition Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Transform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Auto Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Activity 4-1: Family Mold Project: Toy Shapes . . . . . . . . . 4-16
Activity 4-2: Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Removing the only instance of a product . . . . . . . . . . . . . . . . . . 4-29

Core and Cavity Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


Parting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Auto Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Auto Search Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Select Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Eject Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Product Design Advisor and Auto Patch . . . . . . . . . . . . . . . 5-4
Traverse Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Edit Parting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Split Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Inspect Crossover Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Split Faces by Imprinting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Subdivide Isocline Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Auto Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Edit Transition Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Add Transition Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Activity 5-1: Parting Curves on a Planar Parting . . . . . . . 5-11
Activity 5-2: Natural Parting with Isocline Curves . . . . . . 5-16
Activity 5-3: Selecting Transition Objects . . . . . . . . . . . . . . 5-25
Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Create Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Extrude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Extrude Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Skip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Bounded Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

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Swept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Enlarged Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Choosing a Parting Surface Type . . . . . . . . . . . . . . . . . . . . . . 5-39
Edit Parting Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Sew Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Auto Cavity_Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Activity 5-4: Parting Surface Creation . . . . . . . . . . . . . . . . 5-42
Extract Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Core and Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Check Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Check Overlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Create Cavity, Create Core . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Activity 5-5: Core and Cavity Regions . . . . . . . . . . . . . . . . . 5-70
Activity 5-6: Diagnostics in the Extract Regions Dialog . . 5-74
Activity 5-7: User Defined Parting . . . . . . . . . . . . . . . . . . . . 5-81
Edit Parting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
Suppress Parting and Update Parting . . . . . . . . . . . . . . . . . . 5-85
Activity 5-8: Topology Change to Product Model . . . . . . . . 5-86
Compare and Swap Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Activity 5-9: Compare and Swap . . . . . . . . . . . . . . . . . . . . . 5-101
Mold Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Mold Base Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Mold Base Index List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Edit Register File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Edit Data Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Rotate Mold Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Edit Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Expression List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Standard Component Size Lists . . . . . . . . . . . . . . . . . . . . . . . 6-7
Activity 6-1: Adding A Mold Base . . . . . . . . . . . . . . . . . . . . 6-8

Standard Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


Standard Parts Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Standard Part Management . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Ejector Pin Postprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Slider and Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Mold Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

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Pocket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3


Other Standard Part Library Functions . . . . . . . . . . . . . . . . 7-4
Standard Part Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Catalog Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Parts List Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Standard Part Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Flip Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Parent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
True / False / Both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Add/Modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Standard Parameter Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Dimension Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Lock/Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Unlock All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Operation Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Edit Register File / Data Base . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Remove Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Reposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Activity 7-1: Adding Ejector Pins and a Sprue Bushing . 7-15
Ejector Pin Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Trim Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Adjust Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Sheet Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Untrim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Trim Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Parting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Mold Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Fit Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Pocket Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Target + Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Target Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Activity 7-2: Post Processing and Pockets . . . . . . . . . . . . . . 7-33
Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Head Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

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Solid Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42


Trim Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Slider and Lifter Sub Assembly Structure . . . . . . . . . . . . . . 7-43
Orientation of Slides and Lifters . . . . . . . . . . . . . . . . . . . . . . 7-44
Activity 7-3: Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . . 7-45

Sub Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Parts as Sub Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Envelope Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Create/Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Definition Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Extrude Edges to Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Sub-insert Part Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Create/Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Parameter Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Foot List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Copy Sub-insert Component . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Edit Register File, Edit Database . . . . . . . . . . . . . . . . . . . . . 8-8
Activity 8-1: Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Gates and Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1


Gates and Runner Systems Overview . . . . . . . . . . . . . . . . . . . . . 9-2
Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Gate Point Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Activity 9-1: Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Runner Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Define Guide String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Sketch Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Curves through Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Add / Remove Curves from Strings . . . . . . . . . . . . . . . . . . . . 9-16
Projection onto parting faces . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

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Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Parting Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Copy Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Create Runner Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Other Runner Design Options . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Reposition and Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Activity 9-2: Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Cooling Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Cooling Component Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Activity 10-1: Cooling Using Standard Parts . . . . . . . . . . . 10-5
Cooling Channel Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Channel Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Balanced and Non-Balanced . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Define Guide Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Create Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Delete Guide Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Delete Guide Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Create/Edit Guide Path Position . . . . . . . . . . . . . . . . . . . . . . 10-23
Add/Remove UG's Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Show Cooling Channel Relationship . . . . . . . . . . . . . . . . . . . 10-23
Generate Cooling Channels . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Hole Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Start Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
End Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Delete Cooling Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Activity 10-2: Schematic Cooling Circuit Design . . . . . . . . 10-26
Electrode Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Electrode Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Standard Part Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Activity 11-1: Electrodes Using Standard Parts . . . . . . . . . 11-4
Insert Electrode Design Approach . . . . . . . . . . . . . . . . . . . . . . . 11-10
Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Definition Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11

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Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Forming Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Selection Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Extrude Edges to Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
EWCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Working Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Electrode Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Point Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Displacement from Reference Point . . . . . . . . . . . . . . . . . . . 11-14
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Z-Level Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Drawing Sheet Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Projection Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Activity 11-2: Electrodes Using Envelope . . . . . . . . . . . . . . 11-17
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Standard Parts Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
All Parts in Mold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
BOM Field Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
BOM Record Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Activity 12-1: Bill of Materials . . . . . . . . . . . . . . . . . . . . . . 12-6
Mold Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
Balloon tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
Activity 12-2: Drafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Additional Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Activity A-1: Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Activity A-2: Bulb Housing . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Activity A-3: Power Tool Casing . . . . . . . . . . . . . . . . . . . . . A-4
Activity A-4: Pager Holster . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Activity A-5: Snap Lock Tab . . . . . . . . . . . . . . . . . . . . . . . . A-6
Activity A-6: Cell Phone Case . . . . . . . . . . . . . . . . . . . . . . . A-7
Activity A-7: Phone Jack Case . . . . . . . . . . . . . . . . . . . . . . . A-8
Activity A-8: Steam Iron Case . . . . . . . . . . . . . . . . . . . . . . . A-9

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Activity A-9: Utility Saw Case . . . . . . . . . . . . . . . . . . . . . . . A-10


Activity A-10: Sprinkler Housing Cap . . . . . . . . . . . . . . . . A-11
Activity A-11: Patch Block with Negative Offset . . . . . . . . A-12
Activity A-12: Engine Casting . . . . . . . . . . . . . . . . . . . . . . . A-19
Activity A-13: Cast Bracket . . . . . . . . . . . . . . . . . . . . . . . . . A-20
Activity A-14: Forged Wrench . . . . . . . . . . . . . . . . . . . . . . . A-21
Activity A-15: Game Controller . . . . . . . . . . . . . . . . . . . . . . A-22
Activity A-16: Coffee Filter Holder . . . . . . . . . . . . . . . . . . . A-23
Activity A-17: Spray Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Activity A-18: Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1

x MoldWizard Design Process EDS MoldWizard V18.0.3


Student Manual All Rights Reserved Unigraphics V18.0.3.2
Course Overview

Course Overview
MoldWizard Design Process

Course Description

MoldWizard is a Unigraphics computer application that automates mold


design. This course will present MoldWizard in a manner that mimics the
Design Process or sequence of tasks commonly used to design a plastic
injection mold. During this course, you will create associative two-part
molds from Unigraphics solid models.

Intended Audience

MoldWizard Design Process is targeted at Unigraphics users who are


responsible for injection mold design and development.

Prerequisites

Students should be familiar with the basic functions of the Motif Interface, and
have taken:

 Practical Applications of Unigraphics course


 Design Applications Using Unigraphics course

OR
 Modeling for Moldmakers course

We highly recommend, but do not require, that the student has:

 Mold design experience


 Experience with Unigraphics Assemblies, UG/WAVE, and Free Form
Modeling

EDS MoldWizard Design Process


All Rights Reserved Student Manual -1
Course Overview

Objectives

After successfully completing this course, you should be able to perform the
following activities:

 Create MoldWizard product assemblies


 Create patch up (shut off) geometry
 Apply a shrink factor
 Create mold tooling inserts
 Define core regions within a product model
 Create associative core and cavity geometry
 Use Mold Base Libraries to choose a standard mold base
 Use Standard Part Libraries to select and position common parts,
including Insert Pockets, Sub Inserts, Cooling Channels, Gates &
Runners, and Electrodes
 Create a Bill of Materials
 Enter the Drafting Application and begin a mold assembly drawing

Student Responsibilities

Experience has shown that you can learn more from this class by:

 Participating Enthusiastically!
 Sharing Experiences
 Giving and Receiving Constructive Feedback
 Asking Questions
 Remaining On Topic"
 Listening Attentively and Taking Notes
 Being On Time
 Having Fun!

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-2 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Course Overview

Student Manual
It is important that you use the Student Manual in the sequence presented.
Later lessons will assume you have learned concepts and techniques taught in
earlier lessons. If necessary, you can always refer to a previous activity where a
method or technique was originally taught.

Lesson Format
The general format for lesson content is:
 presentation
 activity
One or more included in most lessons
 project
 summary

Activities
All activities in this manual will follow a Step and Action Box format.
A Step describes what is to be accomplished in that portion of the activity. Steps
provide general instructions:
Step 1 Define Parting Lines.
Indented below each step will be one or more Action Boxes that describe how to
accomplish the step. Action boxes provide specific detailed instructions:
 Select the Parting Icon.
As your knowledge and skill in the use of MoldWizard increases, you will find
that the general Step instructions may be all you need to accomplish a given task.
When working through lesson activities, remember to use the Cue and Status
lines for additional cues and information on how to accomplish specific tasks.

Workbook
This course also includes a companion Student Workbook. The workbook will
provide an opportunity to apply the skills learned through lecture and activities
to a real life situation, without specific detailed instructions. The workbook
project for this course will be to create mold tooling for a plastic Toy Wagon
Assembly.

EDS MoldWizard Design Process


All Rights Reserved Student Manual -3
Course Overview

Classroom System Information

Your instructor will provide you with the following:

Student Login: Username:

Password:

Path to mdp_student_home directory:

Instructor:

Date:

Class Standards for Unigraphics Part Files

MoldWizard Design Process uses standards that are distinct from other
Unigraphics Instructor Led Classes.

Layer usage, part naming, and considerable automatic geometry creation, all
follow standards set by MoldWizard defaults. These standards and defaults will
be explained as they are encountered in the course.

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-4 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Course Overview

Parts Directory Structure

Home Directory

The Windows Explorer file structure


illustrated is the same for a Unix classroom.

Assemblies will be organized within your home


directory, typically named moldwizd" or
mldwiz00" where 00 will be replaced by a unique
number for each student in the class.

We use moldwizd" throughout this book to


represent any name you have for your home.

Projects are grouped by plastic product, in


Product Directories.

Product Directories

To find previous work or staged assemblies, begin


from your home, open the appropriate product
directory, hub2 for example, then open the top level
part in that directory, for example mdp_hub_top.

EDS MoldWizard Design Process


All Rights Reserved Student Manual -5
Course Overview

Staged Assemblies

Many assemblies are used in this class. Some contain dozens of parts. To
maintain a real-life environment, some of the assemblies are used for multiple
activities.

The class materials contain staged assemblies for every activity except for several
very short and simple introductory activities in the next lesson.

If for any reason you fall behind the class with a tooling assembly that is used
more than one time, please make use of the staged assembly provided.

Spare Parts and Assemblies

MoldWizard creates a great number of new part files in tooling assemblies, and
it very often modifies assembly structures as you perform normal work.
Assemblies and their containing folders (directories) must be read / write in
order to permit you to perform the actions required to learn.

In a learning situation, this read / write property will occasionally lead to one or
more files being modified in a way that was not intended.

If an inadvertent action damages a staged assembly, consult your instructor. If


the instructor recommends that you replace the assembly with a new one:

 Do not hesitate to ask the instructor to help with these steps.


 Using operating system functions for whatever system you have, delete
every file in the folder where the damaged assembly resides.
 Locate a corresponding folder of the same name inside the read only
...Ă/Ămoldwizd / parts folder. This parts folder contains a spare copy of all
folders (directories) used in the class, and their contents.
 Use any File Copy function on your computer to copy all files from
inside the corresponding parts folder into your now-empty directory of
the same name.
 Begin the activity again.

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-6 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
Introduction To MoldWizard ÏÏÏ
Lesson 1
ÏÏÏ
1
ÏÏÏ

PURPOSE This lesson is an overview of the major features of the


MoldWizard Design Process. Details of this process will be
covered in the remainder of the class.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Start the MoldWizard application and navigate through the


student home directory file structure.
 Follow the overall MoldWizard Design Process and recognize
how the MoldWizard toolbar describes the process.
 Observe how MoldWizard automatically updates a mold
design to reflect changes made to the original part model.

This lesson contains the following activities:

Activity Page
1-1 Starting Unigraphics and MoldWizard . . . . . . . . . 1-4
1-2 Beginning a Mold Project . . . . . . . . . . . . . . . . . . . . 1-10
1-3 Mold Csys Orientation and Shrinkage . . . . . . . . . . 1-18
1-4 Defining the Work Piece and Layout . . . . . . . . . . . 1-25
1-5 Parting, Core, and Cavity Definition . . . . . . . . . . . 1-39
1-6 Adding a Mold Base and Standard Parts . . . . . . . 1-60
1-7 Design Changes and Associative Tooling . . . . . . . 1-81

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-1
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ What Is MoldWizard?
ÏÏÏ
1
ÏÏÏ MoldWizard is a process application for design of plastic injection and other
types of molds. MoldWizard's advanced modeling tools for the creation of
cavities, cores, slides, lifters and sub inserts are easy to use and provide fast,
associative, 3D solid results.

MoldWizard automates the difficult and time consuming tasks of mold


design. It does so in an increasingly associative way: if the product design is
altered, related elements of the mold design will automatically update to
reflect the new design.

Moldbase and component libraries include parametric moldbase assemblies


from a variety of catalogs. Catalog and custom components, including slides
and lifters, are accessed via a Standard Parts function that allows users to
associatively place components. Users may customize or extend MoldWizard
libraries to achieve a professional, reusable result without programming
knowledge.

Prerequisites

To effectively use MoldWizard, the user should be familiar with mold design
and possess working knowledge of the following Unigraphics applications
and tools:

 Feature Modeling

 Free Form Modeling

 Curves

 Layers

 Assemblies and the Assembly Navigator

 Changing the Display and Work Part

 Adding and Creating Components

 Creating and Replacing a Reference Set

 WAVE Link Geometry

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1-2 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
Introductory Lesson Structure ÏÏÏ
ÏÏÏ
1
In this lesson you will initialize a MoldWizard project and go through the
MoldWizard Design Process to create a plastic injection mold that will
ÏÏÏ
produce a Business Card Tray.

This lesson is only an introduction to the MoldWizard Design Process.

It is intended that you achieve only an understanding of the overall process,


and gain insight into how later lessons fit into this process.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-3
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Activity 1-1: Starting Unigraphics and MoldWizard
ÏÏÏ
1
ÏÏÏ
Your instructor will provide a user name and password to log into your work
station, and if necessary point out the procedure to start Unigraphics.

Step 1 Log on, Start Unigraphics and enter the MoldWizard


application.

 If Unigraphics is not already running, please start it now.

 Choose Application  MoldWizard.

The MoldWizard toolbar displays.

Step 2 Dock" the MoldWizard tool bar.

TIP Some people prefer to dock the toolbar on the left side of
the screen. Located there, it doesn't move when you change
between Unigraphics applications.

Step 3 Hold the cursor over the various MoldWizard toolbar icons.
The functional name of each icon briefly displays as you hold
the cursor over it.

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Introduction To MoldWizard

ÏÏÏ
Step 4 Using File  Open, examine the directory structure.
ÏÏÏ
ÏÏÏ
1
The file structure on Unix systems is the same as the
Windows NT structure pictured below: ÏÏÏ
Student Project
Home Directory Directories

The parts subdirectory structure is read only."

Step 5 Choose Cancel in the Open Part File dialog.

This concludes Activity 1-1.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-5
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ The MoldWizard Design Process
ÏÏÏ
1
ÏÏÏ The MoldWizard Design Process requires a Unigraphics 3D solid part model
that is moldable as designed:
 We recommend that solid models be modeled in Unigraphics.
 If the solid model is not moldable as designed, we recommend that you
correct it using standard Unigraphics modeling techniques. Correct
models will take full advantage of MoldWizard automation.
The first steps in the diagram below represent the High Level Preparation
process of creating and evaluating a part model for moldability. Once the
part model is moldable, use MoldWizard Design Functions to determine how
the part will be molded.

High Level Preparation MoldWizard Design Functions

Intialize:
Create suitable Define Parting
 project name
solid model Sheets
 location
 units

Use Design
Define:
Advisor to verify: Add the
 orientation
 draft Moldbase
 shrinkage
 parting  work piece

MoldWizard Add:
No
Acceptable? Product Design  ejectors
Advisor  slides, lifters
 sub inserts
Yes
Complete the design
Plan: No with:
Acceptable?
 side actions  gates
 layout  runners
 sub inserts  cooling
 ejection Yes
 electrodes
 gating  pockets
 cooling Patch Holes  Bill of Mat'ls
 electrodes  Drafting

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1-6 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
The MoldWizard toolbar icons represent steps of mold design. They are
ÏÏÏ
organized in an order that closely matches the process flow chart shown on
ÏÏÏ
1
the preceding page.
ÏÏÏ

Load Shrink Tools Standard Sliders Gate Cooling


Mold Bill of
Product Parts and
Work Piece Parting Trim Material
Lifters Runners
Family
Layout Mold Base Electrodes
Mold Pockets Mold
Ejector Sub Drawings
Mold
Pins Inserts
CSYS

Fixed Half A Plate B Plate Moveable Half Ejector Plate

Ejector Plate
Return Pins Supports

Retaining Ring
&
Sprue Bushing

Mounting Plate Cavity Insert Ejector Core


(Inside A Plate) Pins Mounting Plate
Insert

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-7
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
Loading A Product and Project Initialization
ÏÏÏ
The first step in the mold design process is to Initialize a mold design Project.
MoldWizard will automatically generate a mold tooling assembly.

 Choose the Load Product icon from the tool bar . . . À

À
 This will open the Open Part File dialog shown below:

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1-8 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
 Selecting a product part file will open the Project Initialize dialog:
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Selecting an existing project “top” file will open this dialog:

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-9
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Activity 1-2: Beginning a Mold Project
ÏÏÏ
1
ÏÏÏ
This activity demonstrates how a product part file is loaded and a mold design
project is initialized.

Product: Business Card Tray


Part File: mdp_tray
Project Name: mdp_tray

Unigraphics should be running with the MoldWizard toolbar visible:

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1-10 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
Step 1 Load the Product part file.
ÏÏÏ
ÏÏÏ
1
 Select the Load Product icon. ÏÏÏ

The file open dialog displays.

 Navigate into the tray folder and select mdp_tray.

The part file loads. The Project Initialize dialog displays:

Step 2 Examine the part and review the initial assembly structure.

NOTE Please Do Not dismiss the Project Initialize dialog.

 Shade (if necessary) and rotate the part to examine the


geometry.

 Choose View → Assembly Navigator, or click the icon:

Note that the Assembly Navigator contains a single entry: mdp_tray

 Move the Assembly Navigator window to a convenient


location, or dock it. Enlarge the Navigator window until it
has room to display about 15 lines.

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All Rights Reserved Student Manual 1-11
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Step 3 Initialize the Project.
ÏÏÏ
1
ÏÏÏ
In the Project Initialize dialog:

 Verify Millimeter as the preferred Unit for this project.

TIP Windows NT systems require a backslash (\) in their


path names, UNIX systems require a forward slash (/).

 Choose OK in the Project Initialize dialog.


The system generates a mold tooling assembly. When the
process is completed the Assembly Navigator displays this
structure:

 Expand the assembly tree by selecting the + signs.

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1-12 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
 Examine the newly generated assembly:
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

MoldWizard automatically saved an assembly structure named mdp_tray_top.

 Cancel the Assembly Navigator window.

NOTE Do not close the parts. The same parts will be used in the next activity.

This concludes Activity 1-2.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-13
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ The MoldWizard Assembly Structure
ÏÏÏ
1
ÏÏÏ How Does it Work?

MoldWizard automatically generated an assembly structure by


Cloning a blank Seed Assembly that exists within MoldWizard.
This Seed Assembly was created using advanced UG Assemblies and
WAVE functions that provide the associative interpart relationships
that are needed to manage a complex mold assembly.

The top" assembly contains all the files necessary for a complete mold tool.

The layout" sub assembly can contain multiple instances of one or several
products. It's function is to manage the location and orientation of each part in
the Mold Base.

The prod" or product sub assembly contains files relevant to a particular solid
shape that is formed by the mold assembly.

MoldWizard identifies the components in the assembly by attributes contained


in the part files, rather than by the part file name. This use of attributes allows
file name customization, if desired.

The seed assembly resides inside the MoldWizard installation directory tree.
Appropriate modifications to the seed structure (by a person with the necessary
permissions) would be reflected in every future tooling project.

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
Define the Mold Coordinate System ÏÏÏ
1
ÏÏÏ
A Mold Coordinate System (Mold CSYS) must be defined with respect to the
part being molded.

By convention:
 The origin of a mold assembly will lie at the center of the Mold Base
 The XC-YC plane of the Mold CSYS will lie where the fixed and
moving plates meet, that, at the principal parting plane.
 The positive ZC Axis will point in the direction in which the molded
part will be ejected from the mold.

Moving Side
Fixed Side

Part will be ejected in the direction of the +ZC Axis.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-15
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Procedure
ÏÏÏ
1
ÏÏÏ 


Orient the WCS to match the desired Mold CSYS.

Select the Mold CSYS icon from the MoldWizard tool bar . . . À

À
 If necessary, choose the Current WCS option . . . Á

 Choose OK . . Â

This dialog may also be used to reposition the Mold CSYS by moving it to the
center of the Product Body or the center of a Boundary Face.

The Lock buttons allow this repositioning to be done while remaining locked
to one of the three principal planes.

More information on this dialog will be presented later in the course.

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
Assign a Shrinkage Value ÏÏÏ
1
ÏÏÏ
Mold cavities and cores must be sized to allow for material shrinkage.

MoldWizard addresses shrinkage by generating a linked copy of the original


product model in a shrink part. This shrink part is used in the process of
defining cavity(ies) and core(s).

Choosing the Shrinkage icon À will open the Edit Scale dialog:

Shrinkage may be assigned using uniform scale in all directions, or with


varying shrinkage factors along the X, Y, and Z axis.
Once applied, you may edit the shrinkage scale feature at any time by
choosing the Shrinkage icon again.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-17
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Activity 1-3: Mold Csys Orientation and Shrinkage
ÏÏÏ
1
ÏÏÏ
Continue work on your mdp_tray project.

Mold CSYS: To orient the part to stand vertical in the mold, the YC
axis must be aligned with the length of the part, as shown below.

Shrinkage: Uniform, 1.005.

Existing Orientation Preferred Orientation


XC-YC plane at principal parting XC-YC plane at principal parting
+ZC is part eject direction +ZC is part eject direction
YC lies along the narrow dimension YC lies along the longer dimension

Step 1 Set the Mold Coordinate System.

 Choose WCS → Rotate...

 Verify that +ZC Axis XC - YC is highlighted.

 Verify the angle is set to 90 degrees.

 Choose OK.

The YC axis should now align with the length of the part, the
XC axis with the narrower width of the part.

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1-18 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
 Choose the Mold CSYS icon. ...À
ÏÏÏ
1
ÏÏÏ
À
The Mold CSYS dialog opens.

 Choose or verify that Current WCS is toggled ON . . . Á

 Choose OK . . Â

The display reorients to match the new Mold CSYS.

 Fit the view.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-19
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Step 2 Assign Shrinkage.
ÏÏÏ
1
ÏÏÏ  Choose the Shrinkage icon .. À

À
The Edit Scale dialog opens.

1.005 Á

Â
When the Edit Scale dialog opens, the Work Part changes. A
linked body in the Shrink Part, mdp_tray_shrink, has an
existing scale feature. Shrinkage edits the scale feature.

 Enter 1.005 in the Uniform edit window . . . Á

 Choose OK . . Â

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1-20 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
Step 3 Save your work, without closing parts.
ÏÏÏ
ÏÏÏ
1
 Choose File → Save All.
ÏÏÏ
NOTE Do not close the parts. The same parts will be used in the
next activity.

This concludes Activity 1-3.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-21
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
Define the Work Piece / Mold Insert
ÏÏÏ
The terms Insert and Work Piece are synonymous.

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1-22 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
Work Piece Dimensions Dialog
ÏÏÏ
ÏÏÏ
1
The Work Piece Dimensions dialog is used to define the type and size of work
piece inserts that will be used to form the cavity and core. ÏÏÏ
Work Piece Types:

Work Piece type selections include a Standard Block or combinations of


independently modeled user defined bodies.

Work Piece Dimensioning Methods:

Two methods for sizing the work piece are offered: Distance Allowance and
Reference Point.

Distance Allowance Method:

The Distance Allowance method references the outer edges of the product
envelope À (dashed lines) plus six offsets to define the work piece Á (Solid
lines). This method will be used in this introductory lesson.

Á
À

MoldWizard will recommend rounded values for a work piece that will contain
the product volume.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-23
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
Define the Work Piece / Cavity Layout
ÏÏÏ Mold CSYS addresses only the orientation of the product in a mold cavity.
Choose the Layout icon À to define how many cavities the mold will contain
and how they will be oriented in the mold.

The Layout dialog is used to define both Rectangular and Circular cavity
layouts. The mold layout can also be edited using this dialog. Features of
this dialog will be covered later in the course.

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Introduction To MoldWizard

ÏÏÏ
Activity 1-4: Defining the Work Piece and Layout ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Continue work on the mdp_tray project.

This assembly uses a HASCO_E Type 1 (F2M2) mold base.

The work piece will be sized to match an available standard plate


thickness of this mold base: 27mm below the parting line, and 56mm
above the parting line.

56mm

P/L
27mm

Step 1 Define the work piece dimensions.

 Choose the Work Piece icon:

This opens the Work Piece Dimensions dialog, and makes


mdp_tray_parting the Work Part.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-25
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ  Edit the Z-Down and Z-Up values to match the intended
ÏÏÏ
1 mold base:
ÏÏÏ Z_Down 27.0 . . À
Z_Up 56.0 . . Á

À
Á

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1-26 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Introduction To MoldWizard

ÏÏÏ
 Choose OK to accept the remaining defaults.
ÏÏÏ
ÏÏÏ
1
 Fit the view.
ÏÏÏ
TIP Values entered in the Work Piece dialog can be edited
by again choosing the Work Piece icon. More often
than not, MoldWizard's recommended insert box size
will be adequate for an initial design.

Step 2 Center the work piece/cavity in the mold assembly.

 Choose the Layout icon:

The Cavity Layout dialog appears, and the work part changes to
mdp_tray_layout.

 Verify that a Rectangular, Balanced, 2 Cavity layout is


specified . . . ÀÁÂ

 Choose Start Layout . . . Ã

À
Á
Â

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-27
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

The Cue line reads Select cavity side." The system expects you
to indicate the side on which you want the new cavity to be
positioned.

 Select the vector direction indicator shown above, closest to


the rounded side of the tray . . . . Ä

 Choose Auto Center . . . Å

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Fit the view.

The layout should appear similar to the illustration above.

Step 3 Add tool bodies to define pockets for the workpieces.

 Choose Insert Pocket.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-29
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

Á
Â

Ã
The Insert Pocket dialog allows you to define tool bodies that
you can later subtract from mold plates. The resulting void
spaces define machined volumes to receive workpieces.

 Set R to 15 . . . Á
 Set type to 1 . . . Â
 Choose OK . . . Ã

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

The pocket is automatically sized to contain the two workpiece


inserts.

 Cancel the Cavity Layout dialog.

Step 4 Save your work, without closing parts.

 Choose File → Save All.

NOTE Do not close the parts. The same parts will be used in the
next activity.

This concludes Activity 1-4.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 1-31
Introduction To MoldWizard

ÏÏÏ
ÏÏÏ MoldWizard Tools
ÏÏÏ
1
ÏÏÏ

The Tools icon accesses a variety of MoldWizard functions to:

 solid split a work piece for slide actions or sub insert geometry.
 solid patch voids within the product model, cavity or core.
 sheet patch complex holes or other open surface areas to define shut
off geometry within a mold.

These MoldWizard tools are used in close conjunction with Parting Functions
to complete complex parting designs.

Patching and the role it plays in mold design will become more apparent as
we preview Parting Functions.

MoldWizard tools will not be required in this introductory lesson.

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Introduction To MoldWizard

ÏÏÏ
Parting Functions ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Patch and parting operations define the extent or boundary of material
belonging to either cavity or core.

Overview of MoldWizard's parting functions:

 Parting Lines will identify


parting edges or natural parting
contours of the product. A sub
function can detect and patch
simple surface openings with
sheet bodies.
 Parting Surfaces will generate
sheet bodies that extend from
perimeter parting edges or
contour to the extremities of the
work piece.
 Extract Regions will interact to
identify the cavity and core faces
of the product.
 Cavity_Core will use the
generated sheet bodies and
identified cavity and core parting
faces to trim cavity and core
bodies from the workpiece.
 Edit Parting and Swap Model
provide means to update parting
geometry if the original product
model is modified.

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ÏÏÏ
ÏÏÏ Parting Lines
ÏÏÏ
1
ÏÏÏ The Parting Lines function is used to identify the perimeter parting edges
and/or natural parting contours of the product.

Other sub features of this function include:

 Split Faces interacts to divide faces that cross the parting.


 Transition Objects bridge complex parting sheets.

Choosing the Parting Lines icon will open the dialog below:

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ÏÏÏ
Choosing Auto Search Parting Lines will open the dialog below:
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

Other sub features of this function include:


 Product Design Advisor analyzes the product model for moldability.
 Auto Patch detects and patches simple holes in the model.

Patching Operations

The parting sheet that will be generated for the tray model À does not account
for two open slot in the product body Á.

Á À
Á

These open areas inside the perimeter of the product require Patch Operations
that can include:
 applying the Auto Patch function, OR
 creating patch sheets and bodies explicitly using Tools functions.

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ÏÏÏ
ÏÏÏ MoldWizard will later use these Patch Sheet bodies, extracted Core and Cavity
ÏÏÏ
1 Regions, and the Parting Surface Sheet body to trim seed blocks for core and

ÏÏÏ cavity.

Trim requires a complete and unbroken set of sheet bodies. Without Patch
(or shut off) geometry to define where the missing" portion of the product is
to be parted, the trim operation that creates the core and cavity would fail.

Parting Surfaces

The Parting Surfaces function is used to generate a sheet body that extends
from the peripheral parting edges and contours of the product to the
extremities of the work piece.

Selecting Parting Surfaces will open the Create Parting Surfaces dialog:

From this dialog, parting surfaces can be created and edited.

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ÏÏÏ
Extract Regions
ÏÏÏ
ÏÏÏ
1
In the context of MoldWizard, extracting regions is the process of defining
which faces (regions) of the product will be used to form the core side (core
ÏÏÏ
regions), and which will be used to form the cavity side of the mold (cavity
regions).

MoldWizard will identify what it believes to be the correct core and cavity
regions. The purpose of the extract regions dialog is to edit (if necessary)
and confirm the cavity and core regions identified by MoldWizard.

Selecting Extract Regions button will open the Extract Regions dialog:

À
Á
Ã

 Ã

Key features of the Extract Regions dialog are Face Counts for the total À,
cavity Á and core  faces, and Slide Controls à to sequentially display
identified Cavity and Core faces, from none to all.

The sum of the cavity and core counts should always equal the total face
count.

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ÏÏÏ
ÏÏÏ Cavity and Core
ÏÏÏ
1
ÏÏÏ Thus far, we discussed:

 the Parting Lines function, used to define the parting line, analyze the
product for moldability and auto patch holes.
 the Parting Surface function, used to create a parting sheet body that
extends from the peripheral parting edges of the product to the
extremities of the work piece.
 the Extract Regions function, used to identify which faces of the
product model belong to the cavity, and which belong to the core.

With the completion of the above steps, the system has the information it
needs to complete cavity and core bodies. Choosing Core_Cavity will open
the Core & Cavity dialog:

Choosing Create Cavity will launch the process that creates the cavity side of
the mold insert.

Similarly, choosing Create Core will create the core side of the mold insert.

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ÏÏÏ
Activity 1-5: Parting, Core, and Cavity Definition ÏÏÏ
ÏÏÏ
1
ÏÏÏ
The parting lies around the bottom perimeter of the tray. The
Parting Line function will automatically determine the parting for a
product as simple as this one.

Given the draft angle detail of the slots (Section AA), shut off" or
patch faces must be created on the cavity side of the tray. The Auto
Patch function will automatically detect and patch these openings.

A Parting Line

Draft

Stationary Moving
Cavity Core
Side Side

A Section A-A
Parting
Line

Step 1 Define the Parting Line and Patch Regions

 Choose the Parting icon:

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ÏÏÏ
ÏÏÏ The Parting Functions dialog opens.
ÏÏÏ
1
ÏÏÏ
À
Á

 Verify that Auto Process is OFF (unchecked) . . . À

 Choose Parting Lines . . . Á

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ÏÏÏ
The Parting Lines dialog opens.
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Choose Auto Search Parting Lines . . Â

The Search Parting Lines dialog opens.

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ÏÏÏ
ÏÏÏ  Choose Apply . . Ã
ÏÏÏ
1
ÏÏÏ MoldWizard identifies and highlights the parting lines.

Product Design Advisor and Auto Patch are now available.

 Choose Auto Patch . . . Ä

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ÏÏÏ
The Patch Loops Selection dialog opens. The Cavity Side option
ÏÏÏ
is enabled by default . . . Å
ÏÏÏ
1
ÏÏÏ
Å

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ÏÏÏ
ÏÏÏ The top edge of both slot openings highlights to indicate two
ÏÏÏ
1 Patch Loops.

ÏÏÏ

Ç
 Choose Auto Patch . . . Æ

MoldWizard creates patch sheet bodies to cover both slots.

 Choose Back . . . Ç

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Choose OK to accept the parting loop previously identified


and highlighted by MoldWizard . . . È

The system displays the parting loop. The Parting Lines dialog
appears.

É
 Choose OK once again, to complete the parting line
definition . . . É

The parting loop changes from green to magenta to indicate it


has been defined.
The Parting Function dialog displays.

NOTE If the Auto Process option had been turned ON in the


Parting Functions dialog, the system would automatically
advance to the Create Parting Surfaces dialog.

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ÏÏÏ
ÏÏÏ Step 2 Create Parting Surfaces
ÏÏÏ
1 The parting line was identified and two openings were patched.
ÏÏÏ You will now create a sheet that will later be instrumental in
dividing the work piece into its cavity and core components.

 Choose Parting Surfaces . . À

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ÏÏÏ
The Create Parting Surfaces dialog opens.
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Choose Create Parting Surfaces . . Á

The following warning dialog appears:

 Choose OK to create a single parting surface . . . Â

The system generates a parting surface and returns to the


Parting Functions dialog.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Ã

 Once again, choose Parting Surfaces . . . Ã

 If necessary, toggle Show Product Model to OFF . . . Ä

 Fit the view.

You should see the parting sheet, and two patch sheets. A large
gap exists in the volume occupied by the product model.
To complete the core and cavity definition, you also need to
extract two sets of faces, one for the core, and another for the
cavity. Each region can fill the void currently displayed.

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ÏÏÏ
 Toggle Show Product Model to ON . . . Å
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Å

 Choose Back to return to the Parting Functions dialog.

Step 3 Extract Cavity and Core Regions.


The parting sheet bodies and product model should be
displayed and the Parting Functions dialog should be open.

 Choose Extract Regions . . . À

The Extract Regions dialog opens.

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ÏÏÏ
ÏÏÏ  Verify the face counts in the Extract Regions dialog:
ÏÏÏ
1
ÏÏÏ Total Faces . . . . . 151 . . Á
Cavity Faces . . . . 94 . . . Â
Core Faces . . . . . 57 . . . Ã

Ä
Ã

 Verify or set the Display Mode to Shaded.

 Use the Slider Bars to identify the cavity and core faces as
they highlight in the display . . . Ä

 Choose OK to accept the system defined core and cavity


regions . . . Å

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ÏÏÏ
Choosing OK indicates that the faces identified for cavity and
ÏÏÏ
core creation appear to be correct.
ÏÏÏ
1
MoldWizard extracts the core and cavity face information and
again opens the Parting Functions dialog.
ÏÏÏ
Step 4 Create the Cavity and Core Blocks

 Set the Display Mode to Wireframe.

 Choose Cavity_Core . . . À

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ÏÏÏ
ÏÏÏ The Core & Cavity dialog opens.
ÏÏÏ
1
ÏÏÏ

 Choose Create Cavity . . . Á


A Select Sheets dialog appears. The parting surface, patch
sheets, and extracted cavity face region are highlighted.

Â
 Choose OK in the Select Sheets dialog.
The system uses the Parting Surface Sheet Body, the two Patch
Sheet Bodies and the Extracted Cavity Face Regions of the product
model to trim an existing seed Cavity block.
The displayed part temporarily changes to the mdp_tray_cavity
component. The following dialog is displayed:

NOTE Do Not OK or Cancel this dialog until you have examined


the newly created cavity!

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ÏÏÏ
 Examine the cavity: mdp_tray_cavity.
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

TIP This Cavity Block, mdp_tray_cavity, is suitable for tooling


development with UG CAM operations.

 Choose OK to return to the Parting Part and the Core &


Cavity dialog . . . Ã

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ÏÏÏ
ÏÏÏ  Choose Create Core . . . Ä
ÏÏÏ
1
ÏÏÏ

Again, the Select Sheets dialog appears.


This time, the parting surface and the extracted core face
regions are highlighted.

 Choose OK in the Select Sheets dialog.


The system uses 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.
The displayed part temporarily changes to the mdp_tray_core
component, and again the following dialog appears:

 Examine the core.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

TIP This Core Block, mdp_tray_core, is suitable for tooling


development with UG CAM operations.

 Choose OK to return to the Parting Functions dialog . . . Å

Å
 Cancel from the Parting Functions dialog.

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ÏÏÏ
ÏÏÏ  Use the Window pull down to change the displayed part to
ÏÏÏ
1 mdp_tray_top.
ÏÏÏ The cavity/core mold inserts display, with the parting parts
suspended inside the mold cavities.

Step 5 Save your work, without closing parts.

 Choose File → Save All.

NOTE Do not close the parts. The same parts will be used in the
next activity.

This concludes Activity 1-5 .

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ÏÏÏ
Adding a Moldbase and Standard Parts ÏÏÏ
ÏÏÏ
1
MoldWizard includes spreadsheet driven Moldbase and Standard Part libraries
that are used to add a mold base and standard parts to the mold assembly. ÏÏÏ
These libraries may be customized and expanded to fit the needs of the user.

Mold Base Management


The Moldbase Library includes catalogs from: HASCO, DME, FUTABA
(metric only), LKM, and OMNI (inch only).
An additional catalog named UNIVERSAL is provided as a template for
creating a customized mold base catalog.
The mold base catalog list for a metric mold is partially shown below:

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ Standard Parts Management
The Standard Parts Library includes catalogs from: HASCO, DME, FUTABA
(metric only), OMNI (inch only) and YATES (inch only). Also provided are
generic catalogs for various Electrode and Insert types.
The standard parts catalog list for a metric mold is shown below:

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ÏÏÏ
Ejector Pin and Create Pockets Function.
ÏÏÏ
ÏÏÏ
1
The Activity that follows this discussion will involve the use of two additional
functions found on the MoldWizard tool bar: Ejector Pin and Create Pockets.
ÏÏÏ

Ejector Pin

Ejector pins are added to the mold assembly from the Standard Parts
Management dialog. Once an ejector pin has been added, a separate post
processing function, the Ejector Pin function, is used to trim the pin to its
proper length and profile.

Create Pockets

While the Standard Parts Management dialog is effective at adding parts to


the mold assembly, it does not create pockets, holes, and openings that are
needed to install these added parts. The Create Pockets function is used to
add these needed solid geometry features.

The following Activity will add:

 A Mold Base
 A Locating Ring
 An Ejector Pin.

The Ejector Pin will be trimmed to its proper length using the Ejector Pin
function.

Finally, pockets will be cut into the mold plates and core portion of the mold
insert using the Create Pockets function.

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ÏÏÏ
ÏÏÏ Activity 1-6: Adding a Mold Base and Standard Parts
ÏÏÏ
1
ÏÏÏ
Step 1 Add a mold base.

 Use Zoom In/Out to adjust the display to about a quarter of


its current size. The display area around the workpiece will
soon be occupied by the mold base assembly.

 Choose the Mold Base icon to open the Mold Base


Management dialog . . À

 Select HASCO_E from the Catalog pulldown menu . . . Á

The dialog displays sizes and values appropriate for a


HASCOE_E Type 1 (F2M2) mold. The dialog also displays a
bitmap image of the moldbase.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

Â
Ã

 Index size 296x296 is preselected, based on L and W


à L, W, Z up, and Z down are values entered in (or calculated by) Layout

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ÏÏÏ
ÏÏÏ  With your attention directed toward the Graphics Area and
ÏÏÏ
1 the Status line, Choose OK.
ÏÏÏ MoldWizard generates the components of the selected mold
base. This process may take a few minutes.
When MoldWizard is finished:

 Fit the view.

The figure below shows the mold base with the tray cavity
nested between the mold plates.

 Change the display to a Front view.


Hint: MB3  Replace_View  Front.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1

Æ
ÏÏÏ

Å
Æ

Ä Plate Component FX_1 (Fixed Half) uses standard plate K20


Å Plate Component MV_1 (Moving Half) uses standard plate K20
² Work Piece Z dimensions exceed default K20 plate thickness (22mm)

TIP Use the Assembly Navigator to confirm component file


names.
You will soon see that the base name of components also
appears in an editing dialog.

We chose values of 56 and 27 mm for the Z-Up and Z-Down


dimensions to match a known standard plate thickness that
would accommodate the tray design.
As the front view reveals, the thicknesses chosen are not the
defaults for the index size needed.
You will use a convenient edit function to adjust individual K20
plate thicknesses to appropriate standard sizes.

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ÏÏÏ
ÏÏÏ Step 2 Edit two K20 plates to suit the work piece.
ÏÏÏ
1
ÏÏÏ  Choose the Mold Base icon . . . . À

 Choose Edit Component . . Á

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ÏÏÏ
The Edit Moldbase Components dialog appears:
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 In the graphics window, select the moving plate indicated in


the illustration . . . Â

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ÏÏÏ
ÏÏÏ The dialog updates to show the standard part file name . . Ã
ÏÏÏ
1 and the catalog designation of the part selected . . . °

ÏÏÏ

 Change the plate thickness by adjusting the plate_h


parameter to 27 mm . . . Å

 Choose Apply.

The plate updates.

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Æ

 Select the fixed plate shown above . . Æ

 Change plate_h to 56 mm.

 Choose OK.

The plate updates, and the Mold Base Management dialog


reappears.

 Choose Cancel.

 Choose File  Save All.

FRONT view with plates edited.

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ÏÏÏ
ÏÏÏ Step 3 Add a standard Locating Ring.
ÏÏÏ
1
ÏÏÏ  Change the display to a TFR-TRI view.
Hint: MB3  Replace_View  TFR-TRI.

À
 Choose the Standard Parts icon . . . À

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ÏÏÏ
The Standard Parts Management dialog opens.
ÏÏÏ
ÏÏÏ
1
ÏÏÏ
Á

 If necessary, choose catalog HASCO . . . Á

NOTE Do NOT choose HASCO_E.

 From the HASCO standard parts list, select the


K100A (Locating Ring) . . Â

 Choose OK.

The Locating Ring is added to the mold assembly. For this


particular component, positioning is automatic.

 If necessary, choose Cancel in Standard Parts Management.

 Using the MB3 menu, set Display Mode to Partially Shaded.

TIP By default, MoldWizard standard parts have the partially


shaded attribute.
Partial shading makes it easier to examine standard part
placement in an otherwise wireframe assembly view.

 Choose File  Save All.

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ÏÏÏ
ÏÏÏ Step 4 Add a standard Ejector Pin.
ÏÏÏ
1 In this introductory activity, only one ejector pin will be added.
ÏÏÏ
 Once again choose the Standard Parts icon:

 Change the Classification field to Ejector Pins . . À

The Classification pull down helps you to select from large


catalogs by filtering the list to display only one type of part.
 Select the Z41 pin from the list . . . . Á

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ÏÏÏ
 Change parameter pin_d to 4.5 . . . Â
ÏÏÏ
ÏÏÏ
1
ÏÏÏ

 Choose Apply.

The view is automatically changed to a TOP orientation. The


Point Constructor dialog displays.

 Choose the Arc/Ellipse/Sphere Center icon . . Ã

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ÏÏÏ
ÏÏÏ  In the graphics window, select an edge of either left arc of
ÏÏÏ
1 the lower slot as shown below . . . Ä
ÏÏÏ NOTE Be careful to select the arc adjacent to the square corner
of the tray. The active tray instance might not be the one
oriented as shown:

NOTE This is only an initial placement. You will adjust the location.

 Choose Back in the Point Constructor dialog.


The Standard Part Management dialog reappears.
The newly placed pin should still be highlighted.

TIP When you specify multiple identical cavities,


MoldWizard will use Unigraphics assemblies capability
to instance each complete product sub assembly.

You need add pins to only one instance of the tray. Other
instances will automatically have the same pins.

Step 5 Locate the ejector pin to push against the bottom of the
part, between the slot and outside edge.
 Choose the Operation tab from the Standard Part
Management dialog . . À

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ÏÏÏ
ÏÏÏ
ÏÏÏ
1
À ÏÏÏ
 Choose Reposition . . Á

The reposition dialog appears.


 Verify that the dialog is in Transform mode . . . Â

 In the X input window, type ±1 . . Ã

NOTE Use plus or minus, as your part dictates, to move the pin
away from the center of the part.

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ÏÏÏ
ÏÏÏ  Press Enter.
ÏÏÏ
1
ÏÏÏ  If the pin moved in the wrong direction, correct it now.

The pin location updates as soon as you press the Enter key.

 In the Y input window, type -5 . . Ä

Å
 Choose OK . . Å

Once again the pin location updates.

TIP Pressing Enter works like Apply. The component will


move, but the dialog will remain open.
When you choose OK, the Reposition dialog will close
and the Standard Part Management dialog will reappear.

 Choose Cancel.

 Using the MB3 menu, choose Orient ViewRight.

Orient View differs from Replace View in that the name of the
view and its shading characteristics are retained.

 Use Zoom to verify that the ejector pin is not trimmed.

MoldWizard automatically positioned the base of the pin on the


moving ejector plate. The top of the pin will now be trimmed to
the correct length.

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ÏÏÏ
Step 6 Trim the Ejector Pin.
ÏÏÏ
ÏÏÏ
1
 Choose the Ejector Pin icon . . . À
ÏÏÏ
À

The Eject Pin Post Processing dialog displays.

The options in this dialog will be explained later in the course.

 Select the Ejector Pin in the graphics window.

 Choose OK to accept the default settings.

The pin is trimmed to match the core insert face.

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ÏÏÏ
ÏÏÏ Step 7 Create Pockets for the Ejector Pin and Inserts.
ÏÏÏ
1
ÏÏÏ
Typically, pockets are created only after the complete mold
design is confirmed. This practice makes editing and
repositioning much easier, by minimizing feature updates.
Since this is only a demonstration, you will create example
pockets now.
Create Pocket operations will be used to create ejector holes
through two mold plates and the core portion of the work piece
insert, and cavities to receive inserts in the applicable plates.

 Choose Create Pockets . . . À

À
 The Create Pockets dialog displays.

 Choose Standard Part . . Á

 Select both instances of the Ejector Pin in the graphics


window.

 Choose Apply.

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ÏÏÏ
Pockets (holes) have now been cut into both mold plates that
ÏÏÏ
intersect with the two ejector pins . . . Â
ÏÏÏ
1
ÏÏÏ

 Â

Â
Â

 Choose Target + Standard . . . Ã

The cue reads Select Target Bodies, then Standard Parts."

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ÏÏÏ
ÏÏÏ  Position your cursor over the core insert, and pause (do not
ÏÏÏ
1 move it) until you see the quick pick cursor indicator . . Ä
ÏÏÏ

 Select the core insert.


Hint: Move the cursor over the numbers in the
Quick Pick Tool Å until the Status area reads
Solid Body : UM_CORE_BLOCK
Click on the corresponding number.

 Choose OK.

When you choose OK, target body selection is completed.


A Standard Parts selection dialog appears, and the cue reads
Select Standard Parts."

 Select the ejector pin.

Both core inserts now have a pocket to receive the ejector.

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ÏÏÏ
Step 8 Create Pockets in plates FX_1 and MV_1 for the insert
ÏÏÏ
blocks.
ÏÏÏ
1
 Orient View to Trimetric. ÏÏÏ
 Choose the Create Pockets icon.

 Choose Standard Part . . À

 Select the pocket cutting body for the inserts.


Hint: Body has dashed yellow lines, looks like this:

 Choose OK.
The mold plates now have pockets to receive the inserts.
 Choose FileSave All.

This concludes Activity 1-6.

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ÏÏÏ
ÏÏÏ Other MoldWizard Design Process Functions
ÏÏÏ
1
ÏÏÏ The following design process functions, not included in this introduction, will
be covered later in this course:

Sliders Gate Cooling


Mold Bill of
and
Trim Material
Lifters Runners
Family
Mold Sub Electrodes Mold
Inserts Drawings

Design Changes
Few mold projects are ever completed without a design change.

The associativity that links the part model to the mold design is one of the key
features of MoldWizard. If a design change is made to the original part
model, the mold design will update to reflect the new design.

There is a powerful provision to swap the product model for a completely


new part. This functionality will assist you greatly if your customer supplies
parts that are not modeled in Unigraphics. This functionality will also be
covered later in the course.

In the following Activity, you will edit the original tray part model using
Unigraphics, and the mold design will automatically update to reflect the
new design.

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ÏÏÏ
Activity 1-7: Design Changes and Associative Tooling ÏÏÏ
ÏÏÏ
1
ÏÏÏ
The Product Design Advisor, which you will learn about later, has revealed that
the part design does not include needed draft on the two back legs of the part.

Step 1 Suppress the parting.

TIP Before performing work that may affect the parting, it is


good practice to:
 Suppress the parting.
 Perform the work.
 Update the parting.

 Open the Model Navigator.

 Choose the Parting icon.

 Choose Suppress Parting . . . À

In a few moments, the parting features are suppressed.


 Verify which features were suppressed by observing the
Status column in the Model Navigator, and notice the
corresponding check boxes for the suppressed features.

Step 2 Examine the existing mold design.


 Use the Window pull down (or if necessary, File  Open) to
display to open the original part model: mdp_tray.

 Set the Display Mode to Wireframe.

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ÏÏÏ
ÏÏÏ  Rotate and Zoom the view to observe the design of the front
ÏÏÏ
1 and rear legs.
ÏÏÏ
Draft On The Front Legs

No Draft On The Back Legs

Step 3 Edit the rear leg feature.

 Choose Application → Modeling.

 Double click over the icon for EXTRUDED(19) . . . À

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ÏÏÏ
The Edit Parameters dialog appears.
ÏÏÏ
ÏÏÏ
1
 From the Edit Parameters dialog, choose Feature
Parameters . . Á ÏÏÏ

Another Edit Parameters dialog displays.

 In the Taper Angle field, type 1.5 . . . Â

 Choose OK in the displayed Edit Parameters dialog.

 While observing the status line, choose OK in the original


Edit Parameters dialog.

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ Status information flashes quickly as features in the tray update.
ÏÏÏ
1 You may be able to see that WAVE linked features in the shrink

ÏÏÏ and parting parts also update.


 Choose FileSave All.
 Examine the taper that has been added to the mdp_tray
part.
The changes you made affect the core region in the parting part.
This is why you suppressed the parting before editing.

Step 4 Update the parting.


 Choose the Parting icon.
 Choose Update Parting . . À

In a few moments, all of the parting features are regenerated,


and the suppressed status is gone from features in the Model
Navigator.

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ÏÏÏ
 Dismiss the Model Navigator.
ÏÏÏ
ÏÏÏ
1

Step 5 Verify the updated mold insert design. ÏÏÏ


The legs are formed in the core side of the mold assembly.

 Use the Window pull down to display mdp_tray_core.

 In wireframe mode, examine the updated mold insert design


and verify that taper has been added to the core area that
forms the rear legs.

Step 6 Save your work.


You will have the option to use your assembly again in the
lesson on standard parts.

 Choose File → Close → Save All and Close .

This concludes Activity 1-7.

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Introduction To MoldWizard

ÏÏÏ
ÏÏÏ
ÏÏÏ
1
ÏÏÏ SUMMARY This lesson provided an overview of the
MoldWizard Design Process. Greater detail will
be provided in later lessons.

You have:

 Loaded a Product and Initialized a Project.


 Defined a Mold Coordinate System.
 Assigned a Shrink Factor.
 Defined Work Piece Dimensions.
 Defined a mold Layout.
 Defined Parting lines
 Created Patch sheets in shut-off areas.
 Created a Parting Sheet.
 Identified and extracted core and cavity faces.
 Created a Core/Cavity mold insert.
 Added and modified a Moldbase.
 Selected and Added Standard Parts.
 Created Pockets.
This lesson also demonstrated that MoldWizard
maintains associativity between a part model and
the mold tooling assembly.

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Initializing A Mold Design Project

Initializing A Mold Design Project


Lesson 2

PURPOSE You will practice several initial steps routinely


performed when you create Mold Design Projects.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
OBJECTIVES Upon completion of this lesson, you will be able to:

 Change Project Initialize defaults and observe the


result.
 Discuss the function of each member of the
MoldWizard assembly structure.
 Analyze a product model to verify draft and parting
considerations.
 Explain the capabilities of the Unigraphics Scale
function.
 Add a user defined" work piece to a project.

This section contains the following activities:

Activity Page
2-1 Changing Project Defaults . . . . . . . . . . . . . . . . . . . 2-11
2-2 Choosing and Setting a Mold Csys . . . . . . . . . . . . . 2-19
2-3 User Defined Work Piece . . . . . . . . . . . . . . . . . . . . 2-29

EDS MoldWizard Design Process


All Rights Reserved Student Manual 2-1
Initializing A Mold Design Project

Load Product
When you first choose Load Product, the Project Initialize dialog appears:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

Unit
In your mold_defaults file:

!---- Project Initialize Default Units -------------------


!
!The Project Initialize dialog allows either inch or metric units projects
!to be created for inch or metric product models.
!The MW_ProjectInitialUnit defines which unit type will be toggled in the
!Project Initialize dialog.
!
! =0, No default unit.
! =1, Metric unit as default
! =2, English unit as default
! =3, Plastic part unit as default
!
MW_ProjectInitialUnit: 3

TIP
When you Load Product for the first time, the Units of the selected
part are displayed in the status window. If you work in mixed units,
always observe the status line to check part units as you initialize.

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Initializing A Mold Design Project

Set Project Path and Name

Browse to a directory where you want your project files to be located . . . À

Proj Path

ÏÏÏ
ÏÏÏ
2
À ÏÏÏ
ÏÏÏ
Á

Name the subdirectory where the mold project files are to be stored . . . Á

MoldWizard will create one level of new directory if a path that ends with a non
existent directory is specified. This depends on the user having appropriate
permissions in the path named.

In iMAN, you must manually create a project Folder and place a reference to
your product part into the Folder. MoldWizard will place references to all new
parts it creates into the same Folder.

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Initializing A Mold Design Project

Proj Name

ÏÏÏ
ÏÏÏ
2
Â

ÏÏÏ
ÏÏÏ
Proj Name defaults to 11 characters. Â The allowed character length a setting
that can be edited in the mold_defaults.def file.

Cloning Process

When you initialize a MoldWizard design project, MoldWizard uses the


Assembly Clone function to copy a MoldWizard seed assembly.

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How Does it Work?

Project initialization actually clones two assemblies.


The project assembly structure consists of the top" part, and
below it var", cool," fill," misc," and layout" parts:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
The product assembly structure consists of a prod" part, and below that the
original model, cavity", core", shrink", and parting" parts. Multiple product
structures may exist within a single project assembly.

An Assembly Navigator view of the prod" seed assembly, as it is stored in the


MoldWizard structure before a product is added, is illustrated:

MoldWizard will first add the product part to the product structure,
representing it by its Empty Reference Set.

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All Rights Reserved Student Manual 2-5
Initializing A Mold Design Project

How Does it Work?

When a project name and product part name are the same:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

When the product name and the product part name differ, as they typically do
for Family Molds:

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Field Separators

Name Field delimiters are controlled in the mold_defaults file. Do not include
separators in names you key in!

MW_ProjectNameDelimiter: _ (underscore)
MW_ProductNameFirstDelimiter: _ (underscore)
MW_ProductNameSecondDelimiter: _ (underscore)

ÏÏÏ
The prefix mdp_" was added to all part names in this class. This prefix is a
departmental standard having nothing to do with MoldWizard.
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Loading a Product

If there is more than one selectable body in the product part, you will be asked to
select a solid.

Do NOT use Load Product to load multiple instances of the same product. We
accomplish instancing using the Layout function.

When you choose Load Product when a MoldWizard assembly is already open,
an additional product is added to the layout sub assembly. We discuss this in
greater detail in the lesson about Family Molds and Layout.

TIP MoldWizard is designed to work with only one project at a time.


Never attempt to use MoldWizard with more than one top level part
open.

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All Rights Reserved Student Manual 2-7
Initializing A Mold Design Project

Project Assembly Members

ÏÏÏ
ÏÏÏ
2 TOP - collects and holds all assembly components and related data
ÏÏÏ

needed to define a mold design.
ÏÏÏ  VAR - contains standard values that may be referenced by mold
bases and standard components. This enables simultaneous
customization of all components that refer to these values.
 COOL - Cooling Channels will be placed here.
 FILL - Gating and Runners will be placed here.
 MISC - standard parts that are not specific to an individual product
insert, such as locating rings, parting locks, and support posts.
 LAYOUT - used to position prod" node(s) relative to the moldbase.
Multi-cavity or family molds have multiple branches under LAYOUT.

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Product Sub Assembly Members

 PROD - files related to an individual product. These include the ÏÏÏ


ÏÏÏ
2
shrink, cavity, core, and parting parts. Product specific standard parts
such as ejector pins, core pins, slides, and lifters may appear in the ÏÏÏ
ÏÏÏ
prod" sub assembly.
 Product model - the original part model is added to the prod sub
assembly with its name unmodified. It is represented by its Empty
Reference Set, thus, it will not be loaded automatically the next time
you open your assembly.

TIP A common source of problems for new users occurs when it is


necessary to open the original part. From Directory" is the default
Load Method" in the Load Options dialog. Since original parts are
frequently not located in the same directory as a tooling project, you
might on occasion need to change your Load Method to As Saved,"
or use File → Open and Filter to the correct directory..

 SHRINK - holds a scaled linked copy of the product model.


 PARTING - holds the parting sheet body, patch sheet bodies and
extracted cavity and core faces used to trim cavity and core blocks.
 CAVITY, CORE - cavity and core work pieces, geometry linked to a
common seed body in the Parting part.
 TRIM - linked bodies in this component are used to trim standard
parts using the Mold Trim function.

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All Rights Reserved Student Manual 2-9
Initializing A Mold Design Project

TIPS
Keep in mind the advice Save Early, Save Often.

Make it a habit to use Save All to be certain you do not lose any
modifications to WAVE linked parts in your project assembly.

Unigraphics will warn you if you attempt to quit with unsaved parts.

Use short project names, and short product names. Unigraphics


places a 30 character limit on the size of a part file name, including
ÏÏÏ
ÏÏÏ
2
the four characters .prt".

ÏÏÏ
ÏÏÏ
The Project Name defaults to 11 characters.

If you have a lengthy file name convention it might be necessary to


copy master files to your project directory, and use abbreviated
product names.

The use of a copy of the master part need not affect MoldWizard's
ability to maintain associativity. As long as a replacement is copied
from the same original, updated file, assemblies will continue to
recognize it; however, all rules regarding Wave parenting" apply.

When you reopen a MoldWizard assembly, remember that the


original part is referenced by it's Empty reference set. Certain
functions, such as Edge Patch and Mold Csys, require this part to be
open. Open the part before using these functions.

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Activity 2-1: Changing Project Defaults

Step 1 Create a mouse project.

 Make sure all parts from previous activities are closed.

 Choose Load Product.


ÏÏÏ
ÏÏÏ
2
 Select .../mouse/mdp_mcu.
ÏÏÏ
ÏÏÏ
mdp_mcu is an abbreviation for MoldWizard Design Process
Mouse Case Upper.

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All Rights Reserved Student Manual 2-11
Initializing A Mold Design Project

 Change Unit to Millimeter . . . À

NOTE The following action is very important!

 In the Proj Name window, type mouse . . . Á

 Verify the above steps in the dialog shown below, and then
choose OK . . . Â

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ À

Â
In a few moments MoldWizard finishes cloning the seed
assemblies and saves your new structure.

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Step 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.

Question:
 How does file naming in your mouse project compare to file
naming in your tray assembly?
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

TIP Toggle the Assembly Navigator off and on with Ctrl-A.

 Choose Assemblies  Reports  List Components.

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All Rights Reserved Student Manual 2-13
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Component Report

Components of moldwizd\mouse\mouse_top.prt : on 06--03--2002 13:51

Part Name Ref Set Name Component Name Count Units Directory

mouse_cool None MOUSE_COOL 1 Mm moldwizd\mouse


mouse_fill None MOUSE_FILL 1 Mm moldwizd\mouse
mouse_layout None MOUSE_LAYOUT 1 Mm moldwizd\mouse

ÏÏÏ
ÏÏÏ
2
mouse_mdp_mcu_prod
mdp_mcu
mouse_mdp_mcu_cavity
None
Empty
None
MW PROD
ORIGINAL PRODUCT
MOUSE_MDP_MCU_CAVITY 1
1
1
Mm
Inch
Mm
moldwizd\mouse
moldwizd\mouse
moldwizd\mouse

ÏÏÏ
mouse_mdp_mcu_core None MOUSE_MDP_MCU_CORE 1 Mm moldwizd\mouse
mouse_mdp_mcu_parting None MOUSE_MDP_MCU_PARTING 1 Mm moldwizd\mouse

ÏÏÏ mouse_mdp_mcu_shrink
mouse_mdp_mcu_trim
mouse_misc
None
None
None
MOUSE_MDP_MCU_SHRINK 1
MOUSE_MDP_MCU_TRIM
MOUSE_MISC
1
1
Mm
Mm
Mm
moldwizd\mouse
moldwizd\mouse
moldwizd\mouse
mouse_var None MOUSE_VAR 1 Mm moldwizd\mouse

All components are positioned as: Absolute

Questions:
 What part is represented by its Empty Reference Set?

 What part has different Units?

 Dismiss the Assembly Navigator and Information windows.

 Leave the project assembly open.

The same project is used in the next activity.

This concludes activity 2-1.

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Mold Csys

Mold Csys transforms a product assembly into mold orientation by


transforming that product sub assembly.

Mold Csys is product specific. Create family members in any convenient


orientation, then adjust each member product to match the mold.

When the mold contain several products, the active product sub assembly is
transformed into the proper mold orientation.
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
NOTE MoldWizard might remind you to open the original part
before editing the Mold Csys.

 Current WCS - set the Mold CSYS to match the WCS.


 Product Body Center - set the Mold CSYS at the center of the
product body.
 Boundary Face Center - set the Mold CSYS at the center of a
selected face.
 Lock Buttons - allow repositioning of the Mold CSYS while
remaining locked on one of the three principal planes.

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Shrinkage

We have seen that choosing the Shrinkage icon opens the Edit Scale dialog.

Once applied, you may edit the shrinkage scale feature at any time by choosing
the Shrinkage icon again, whenever the top part is displayed.

ÏÏÏ
ÏÏÏ
2
Edit Scale Dialog Options

ÏÏÏ
ÏÏÏ Type

Uniform - scale uniformly in all directions.

Axisymmetric - scale with a specified scale factor (or multiplier), symmetrically


about a specified axis. This involves assigning one scaling factor along an axis
you specify, and another, single scaling factor to be applied to the other two axis
directions.

General - scale with different factors in all three X, Y, Z directions.

Uniform General
Axisymmetric

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The illustration below shows the effects of the three types of Scale Body feature
on simple block and cone shapes.

Before Scale

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Uniform Scale Factor 2.0

General Scale
Scale Factors:
X Axis 2.0 Axisymmetric Scale
Y Axis 1.0 1.0 along ZC axis, 2.0 Other
Z Axis 0.5 Directions

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Scale Selection Steps

There are four basic selection steps. Availability of each step depends upon the
selected scaling Type.

ÏÏÏ
ÏÏÏ
2
Body - Lets you select one or more solid or sheet bodies for the scale

ÏÏÏ
ÏÏÏ
operation. This step is required for all three Type methods.

Reference Point - Lets you specify a reference point from which the scale
operation is centered. The default reference point is the origin of the current
WCS, though you can specify another using the Point Method subfunction. This
step is available only with the Uniform and Axisymmetric Types.

Reference Axis - Lets you specify a reference axis for the scale operation.
Available only with the Axisymmetric Type method. The default is the WCS Z
axis. You can change this using the Vector Method subfunction.

Reference Csys - Lets you specify a reference coordinate system when using
the General Scale method.

Reference Geometry

Any geometry you select as an origin or csys reference in the scale dialog
becomes associated to the scale feature.

Scale Factors

Lets you specify the scaling factors (multipliers) by which the current size is to
change. One, two, or three scale factors are required for scale Type Uniform,
Axisymmetric, or General, respectively.

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Activity 2-2: Choosing and Setting a Mold Csys

Continue to work with your mouse project.

Step 1 Determine where the parting should be placed.

NOTE Only if needed, a staged assembly for this activity is in:


.../ moldwizd/ mouse_2 / ÏÏÏ
ÏÏÏ
2
Procedure to open the staged assembly, if needed:
 Verify that no parts are open.
ÏÏÏ
ÏÏÏ
 Verify that Application  MoldWizard is active.
 Open mouse_top in .../moldwizd/mouse_2
 Orient View to Front.
The WCS of the upper case, as modeled, is positioned relevant
to its product assembly, at the center of a circular opening
where the mouse ball protrudes through the lower case.

Make this the main


parting plane

The orientation of the WCS is fine for the upper case, but the Z
level of the origin is not convenient for 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 cavites.
In our scenario, you decide to locate the WCS in the same plane
as the apparently flat section shown at right side of the part in
the illustration above.
This plane is 12.7 Mm above the current location of the WCS.

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Step 2 Move the WCS to the desired parting.

 Choose WCS  Origin...

 If necessary, Reset the Point Constructor to zero all three


numeric input fields.

 Key in 12.7 in the ZC input window.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Choose OK.

The WCS is relocated to the flat end plane of the case:

 Cancel from the Point Constructor dialog.

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Step 3 Set the Mold Coordinate System.

 Choose the Mold CSYS icon.

The Mold CSYS dialog opens:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
À

 Verify that Current WCS is toggled ON . . . . À

 Choose OK.
The mouse_mdp_mcu_prod sub assembly is translated 12.7 mm
downwards (along ZC-) in the mouse_layout structure.

Step 4 Assign a Uniform shrinkage scale factor of 1.005.

Step 5 Save your work.

 Choose File  Close  Save All and Close.

Your mouse project will be used again, much later in the class.

This concludes activity 2-2.

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All Rights Reserved Student Manual 2-21
Initializing A Mold Design Project

Instruction Format for Initializing a Project

You will repeat steps very similar to those used with the tray and mouse projects
many times as you progress through this class.

Reading detailed instructions for many simple, repetitious steps could create
danger of overlooking occasional important differences.

From this point forward, project initialization steps will be condensed into a

ÏÏÏ
short table. Details will be given only as required. Frequently, you will simply
accept default values for every input mentioned in such tables.
ÏÏÏ
2
ÏÏÏ
ÏÏÏ Path names vary. The variable part of the file path is abbreviated to ..."

Examples of initialization instruction format:

Step 1 Initialize a tray project:


First Part .../tray/mdp_tray
Units default (Inch)
Proj Name default (mdp_tray)
Mold Csys specified later
Shrinkage Scale Factor 1.005

Step 1 Initialize a mouse project:


First Part .../mouse/mdp_mcu
Units Millimeter
Proj Name mouse
Mold Csys specified later
Shrinkage Scale Factor 1.005

NOTE It is acceptable to assign Shrinkage before you set the Mold


Csys.

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Work Piece

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

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All Rights Reserved Student Manual 2-23
Initializing A Mold Design Project

Work Piece Options

NOTE Previously defined core and cavity inserts may be replaced


using the Work Piece function.

Standard Block makes use of geometry linked predefined seed blocks.

Cavity Side
ÏÏÏ
ÏÏÏ
2
Core Side

ÏÏÏ
ÏÏÏ User Defined Inserts: Cavity Only, Core Only, Cavity and Core
User Defined insert boxes may be used when the size and shape of the insert
block is something other than a standard rectangular block, or if the core &
cavity require rectangular insert blocks that are different in size.

A user defined work piece must exist in the parting part, but there are several
options for how it is modeled. It may be modeled in the parting part, a
geometry linked component , a user defined feature or an imported part.

NOTE The parting part contains a linked copy of the shrink body. When
the product dimensions are calculated the system will take into
account whatever shrink has been assigned.

An advantage may be gained by importing a Standard Part as a Work Piece.


Sub components may be attached and pocket-cutting bodies may be included
with detailed features. These ideas are expanded more fully in the lesson on
Standard Parts.

The A and B plates of the Moldbase may be geometry linked into the parting
part and used as Cavity and Core inserts. In some cases it will be necessary to
add material to the cavity and core blocks before trimming the cavity and core.

When any of the three insert box type options other than Standard Block are
selected, you will be prompted to select a solid body in the parting part to
represent the insert box. The body must exist in the parting part. You may
create it there, or link it into the parting part.

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Cavity & Core

The user defined insert body will to be shared by the cavity and core.
MoldWizard will use WAVE to copy the body you select. Later it will
automatically trim one copy on each side of a parting sheet.

Cavity Side ÏÏÏ


ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Core Side

Cavity Only, Core Only

A separate user defined body may be selected for each tool insert. Select Cavity
Only and Core Only (in turn) and identify the user defined solids that represent
their respective insert box shapes.

Cavity Side

Core Side

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Work Piece Dimensioning Methods:

Two methods for sizing the work piece are offered: Distance Allowance and
Reference Point. Both refer to the frame of reference used to size the work piece.

Distance Allowance Method

The Distance Allowance method references the outer edges of the product
envelope . . . . À
ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ À

Reference Point Method

The Reference Point method references a defined point on the product . . . Á

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Product Maximum Dimensions

This field lists the X, Y, Z-Up and Z-Down dimensions of the envelope that
contains the shrink part.

ÏÏÏ
ÏÏÏ
2
Z-Up and Z-Down represents the distance from the parting line to the
respective Up & Down extremities of the part. ÏÏÏ
ÏÏÏ
Work Piece Dimensions

MoldWizard will recommend rounded values for an insert box that will
adequately encompass the volume of the parting part. By default, it suggests
a rounded allowance of approximately one inch around the entire part.

Values you enter in the six plus or minus" windows at the left of the dialog
are used to calculate the rounded size. Values entered in the four windows at
the right of the dialog will be used exactly.

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Workpiece Default Settings

The rounding allowance, default method, layer, and layer category name for
the work piece are controlled in the mold_defaults file:

!---------------Work Piece Offset ----------------


!The MW_WorkPieceOffset value specifies the minimum amount that the calculated
!workpiece box will be larger (per side) than the product model.

MW_WorkPieceOffset: 2.500

ÏÏÏ
ÏÏÏ
2
!Note: This value is metric and assumes the MW_DefaultsUnit: variable is set to Metric
!
!------------------Work Piece Reference Point ---------------------------------

ÏÏÏ
ÏÏÏ
!The workpiece dialog has two methods for defining the workpiece dimensions
!The Distance allowance method is centered on the product body.
!The Reference Point method is centered on the absolute csys or a specified point
!The variable defines which method will be default in the dialog.
!
! =0, Distance Allowance
! =1, Reference Point
!
MW_WorkPieceMethod: 0
!
...

!---------------- Work Piece ---------------


!
MW_WorkPieceLayerName: WorkPiece
MW_WorkPieceLayer: 20

NOTE Values in the mold_defaults file are initially all metric. A special
default specifies the units used in the default file. This permits
MoldWizard to control automatic unit conversion as necessary:
MW_DefaultsUnit: Metric

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Initializing A Mold Design Project

Activity 2-3: User Defined Work Piece

Step 1 Initialize the hub project using the information provided


below:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

First Part .../hub/mdp_hub


Units default (Inch)
Proj Name default (mdp_hub)
Mold Csys default
Shrinkage Scale Factor 1.005

Step 2 Create a body suitable for a user defined workpiece.


In the interest of conserving classroom time, we have supplied
construction steps for an appropriate cylindrical body.

 Window to mdp_hub_parting and Fit the view.

 Make layer 2 the Work Layer.

 Choose Application  Modeling.

 Choose Insert  Form Feature  Cylinder...

 Choose Diameter, Height.

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All Rights Reserved Student Manual 2-29
Initializing A Mold Design Project

 In the Vector Constructor, choose ZC Axis, then OK.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ

 Enter the following parameters, and choose OK.

Á
Â

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Initializing A Mold Design Project

 In the Point Constructor, choose Reset to clear previous


input, enter ZC -0.75 (notice the negative value) then
choose OK.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
Á

 Choose Create.

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All Rights Reserved Student Manual 2-31
Initializing A Mold Design Project

A cylinder appears, completely encompassing the volume of the


product model.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ  Cancel from the Vector Constructor.

Step 3 Identify the cylinder as the work piece.

TIP When you enter Modeling, the MoldWizard toolbar may


not be displayed. If this is the case, either:
 Choose Application Õ Gateway...

or
 Remain in modeling, use the MB3 menu over a
toolbar area to activate the MoldWizard toolbar.

 Choose the Work Piece icon.

 Choose the option Cavity_Core.


The dialog changes to the configuration illustrated below:

Á
Â

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2-32 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Initializing A Mold Design Project

 Make layer 2 Selectable.

 Select and confirm if necessary the cylindrical body you just


created.

 Choose OK in the Work Piece Dimensions dialog.

MoldWizard has identified the body you selected as the work


piece.

Step 4 Define Parting Lines.


ÏÏÏ
ÏÏÏ
2
Removing the work piece cylinder from the display will better
illustrate the elements of this step: ÏÏÏ
ÏÏÏ
 Make layer 1 the Work Layer and layer 2 Invisible.

 Choose the Parting icon.

 Set/Verify Auto Process to OFF (unchecked).

 Choose Parting Lines.

The Parting Lines dialog opens.

 Choose Auto Search Parting Lines.

The Search Parting Lines dialog opens and the body highlights
with a vector arrow pointing up.

 Choose Apply.

The external parting loop highlights:

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All Rights Reserved Student Manual 2-33
Initializing A Mold Design Project

Step 5 Auto Patch the interior hole.

 Choose Auto Patch in the Search Parting Lines dialog.

The Patch Loop Selections dialog opens and the internal parting
loop highlights:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
 Choose Auto Patch again, in the Patch Loops Selection
dialog.

A Sheet body is created to patch the interior loop.

 Choose Back.

The Search Parting Lines dialog appears.

 Choose OK in the Search Parting Lines dialog.

The Parting Lines dialog opens and the exterior parting loop is
displayed in green.

 Choose OK in the Parting Lines dialog to accept the


displayed parting loop.

The Parting Functions dialog opens. The parting loop changes


from green to magenta. This color change is a visual cue that
the suggested parting loop has been accepted as the parting line.

Step 6 Create a parting sheet.

 In the Parting Functions dialog, enable Auto Process.


(checked)

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2-34 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Initializing A Mold Design Project

 Choose Parting Surfaces.

The Create Parting Surfaces dialog opens.

 Choose Create Parting Surfaces.

The following Warnings dialog opens:

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
 Choose OK in the Warnings dialog.

The Auto Process feature causes the Extract Regions dialog to


open.

 Fit the view if the entire parting sheet is not visible.

Step 7 Identify core and cavity faces.


Observe the action of Extract Regions on the feature list.

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All Rights Reserved Student Manual 2-35
Initializing A Mold Design Project

 Open the Model Navigator window.

The most recent feature is CAVITY_EXTRACT_BODY, a


copy of CORE_SURF_TRIMMED_SHEET.

 In the Extract Regions dialog, choose OK.

The extracted region features appears at the end of the feature


list.
The Auto Process feature causes the Cavity & Core dialog to
ÏÏÏ
ÏÏÏ
2
open.

ÏÏÏ
ÏÏÏ
 Close the Model Navigator window.

Step 8 Create tooling inserts.

 In the Core & Cavity dialog, choose Create Cavity.

A Select Sheets dialog opens.

 Choose OK in the Select Sheets dialog.

The Cavity Insert is 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 & Cavity dialog reappears.

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Initializing A Mold Design Project

 In the Core & Cavity dialog, choose Create Core.

A Select Sheets dialog opens.

 Choose OK in the Select Sheets dialog.

ÏÏÏ
ÏÏÏ
2
ÏÏÏ
ÏÏÏ
The core insert is displayed.

How Does it Work?


When the cylinder was identified as the work piece,
MoldWizard updated the WAVE linked bodies to point to the
cylinder instead of the default rectangular seed block.
To create the cavity, a copy of the cylinder was trimmed using
the extracted Cavity Face Regions, the patch sheet, and the
parting sheet.
To create the core, a copy of the cylinder was trimmed using the
extracted Core Face Regions, the patch sheet, and the parting
sheet.

 Choose OK.

Step 9 Save your work.

 Chose File  Close  Save All and Close.

Later, you will use the hub assembly to create a circular layout.

This concludes Activity 2-3.

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All Rights Reserved Student Manual 2-37
Initializing A Mold Design Project

SUMMARY We discussed the activities surrounding a mold

ÏÏÏ
project intialization. You had a preview of

ÏÏÏ
tooling development process functions that will
2 be explained in detail in the following lessons.
ÏÏÏ
ÏÏÏ In this lesson you:
 Initialized new mold projects.
 Reviewed the MoldWizard Assembly
Structure.
 Set Mold Coordinate Systems.
 Reviewed the Scale function used for
Shrinkage Factors.
 Created a user defined work piece and
corresponding mold inserts.

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2-38 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Parting Preparation

Parting Preparation
Lesson 3

PURPOSE You will learn methods and procedures used to prepare the
Parting Part for its role as WAVE parent of the cavity and core.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Use the Product Design Advisor to analyze a


product model.
 Apply Solid Patch Up methods that include:
 Solid Patch.
ÏÏÏ
ÏÏÏ

 Planar Patch.

Learn about and use Sheet Patch Up methods that include:


ÏÏÏ
3
ÏÏÏ
 Surface Patch and Edge Patch.

 Patching with Existing Surfaces.

 Using Enlarge Surface.

 Learn and use solid Split Methods.


 Use the Create Patch Block function.
This section contains the following activities.

Activity Page
3-1 Product Design Advisor . . . . . . . . . . . . . . . . . . . . . . 3-4
3-2 Planar Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-3 Surface and Edge Patches . . . . . . . . . . . . . . . . . . . . 3-22
3-4 Patch Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-5 Solid Patch Compensation in the Tool . . . . . . . . . 3-41
3-6 Enlarge Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

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All Rights Reserved Student Manual 3-1
Parting Preparation

Tools

MoldWizard offers a robust set of Tools for


Parting Preparation.

When a product model has holes or gaps in


the natural" parting, the moldmaker must
define geometry to represent shut off faces.

A shut off is an area where core and cavity


steel contact each other directly in the mold.

It is necessary to define geometry in shut off


areas for two reasons:

 CAM requires geometry to position


a cutter on the core or cavity steel.
ÏÏÏ This is true whether the shut off is

ÏÏÏ complex or a simple plane.

ÏÏÏ
3
ÏÏÏ
 Unigraphics requires a contiguous
sheet to trim a workpiece to the
core or cavity contours.

You used Auto Patch earlier. Auto Patch is


an example of MoldWizard's ability to define
the geometry of shut off faces.

MoldWizard Tools provide several options to


cover cases unsuitable for auto patch.

The Tools dialog also provides access to the


Product Design Advisor, a powerful aid to
verify whether the as designed" parting and
draft of a part are suitable for molding.

In later lessons you will learn that


MoldWizard Tools include other important
capabilities.

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3-2 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Parting Preparation

Product Design Advisor

Product Design Advisor offers a wealth of information about how the product
incorporates or fails to incorporate draft, undercuts, and holes to be patched.

TIP Product Design Advisor can be used to verify the original part
even before a tooling assembly is initialized. Just open the part,
activate the MoldWizard application, and choose Tools. The
advisor will be available.

The Product Design Advisor provides face highlighting and if desired,


permanent color editing, for faces that:

 belong to core or cavity


 cross over between the two sides
have little or no draft
ÏÏÏ


ÏÏÏ
Procedure ÏÏÏ
3
ÏÏÏ
1. Choose a radio button that
applies to faces.
2. Optionally choose a color.
3. Choose Apply.

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All Rights Reserved Student Manual 3-3
Parting Preparation

Activity 3-1: Product Design Advisor

In this activity we will discover how the Product Design Advisor can be used to
evaluate a part even before beginning your mold project. This approach could
typically be used to help you estimate the amount of work for the mold, helping
you in the quote process.

Step 1 Open the part mdp_attachment.

NOTE No MoldWizard functions are required at this step.

 Use File → Open.

 Filter to .../pda and open mdp_attachment.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

Step 2 Activate Product Design Advisor

 From the MoldWizard tool bar choose the Tools icon.

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Parting Preparation

 From the Tools dialog choose the Product Design Advisor.

MoldWizard evaluates your part. The ejection direction is


assumed to be parallel to your current Z axis of your WCS.

TIP If a part is not oriented correctly, first move the WCS to


the correct position, and only then open the Product
Design Advisor.

Step 3 Inspect the part

 If necessary, switch your display to Shaded mode.

 Choose the Positive Faces option from the Product Design


Advisor dialog . . . À

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Rotate your part to review the Cavity side.

Are all faces in the Cavity highlighted? What can you assume
about the small faces inside openings?

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Parting Preparation

 Choose Negative Faces from the dialog . . . Á

Á
 Rotate the part to see the Core side.

Notice that not all of the faces have been highlighted. This
indicates that the faces may not have the proper draft applied.

ÏÏÏ
ÏÏÏ
 Now choose Small Angle Faces . . . Â

ÏÏÏ
3
ÏÏÏ TIP If Small Angle Faces is not available, enter a value in the
Draft Angle < field, 3.0 for this part, and choose Apply.

Â
In this case we can see there are 44 faces that have a draft angle
less than 3 degrees.

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Parting Preparation

 Change the Draft Angle to 1.0 degrees . . . Ã

 Choose Apply.

 Once again choose Small Angle Faces.

ÏÏÏ
The number of Small Angle Faces has decreased from 44 to 10.
ÏÏÏ
 From the Product Design Advisor dialog, make sure the
Change Color option is enabled . . . Ä
ÏÏÏ
3
ÏÏÏ
 Choose Pink for the color . . . Å

 Choose Apply.

Ä Å

You have now permanently" changed the color of the faces


with less than 1 degree draft to Pink.

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All Rights Reserved Student Manual 3-7
Parting Preparation

 Choose the Vertical Faces option from the dialog . . Æ

Æ
 Change the color to Yellow.

ÏÏÏ  Choose Apply to change the undrafted faces to Yellow.

ÏÏÏ
ÏÏÏ
3
ÏÏÏ



Verify that Crossover Angle > is set to 5.0.

Now choose the Crossover Faces option.


This indicates that there are 10 faces that cross parting. Later in
the class we will address a function that will assist you to
subdivide those faces.
 Choose Undercut Areas from the dialog. Change the color to
Green and choose Apply.

Undercut Areas shows you areas that have negative draft. These areas need to
be corrected, or, the customer will have to accept the additional cost of adding
a slide or lifter where possible.

Shaded images returned to your customer are helpful in communicating the


problems with the model.

Step 4 Save and Close the part.

This concludes Activity 3-1.

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Parting Preparation

Patch Up Overview

Many, perhaps most, part designs include a hole or slot on the face of a part
that requires a shut off." Where a shut off is used a patch is required. Sheet
Patches are used to cover a surface opening and identify from which side the
tool steel should emerge. Solid Patches are used fill a void with material that
can later be added to the cavity, core, or side action component of the mold to
compensate for face and edges removed by the patch.

The Parting part initially contains a solid body linked to a parent body in your
shrink part, and some seed objects. One of these seed objects is the parent body
for the work piece. There are also seed sheets" linked to the core and cavity
parts.
MoldWizard produces insert tooling by trimming bodies linked to the work
piece seed in your parting part. Common parting faces and regions" or sets of
faces from the core or cavity areas of the parting part are attached to the seed
faces mentioned above. The resulting core and cavity trim sheets are used to
trim bodies in your tooling parts. Unigraphics can not use these faces to trim if
there are gaps adjacent to parting edges or holes in the interior of the trim
sheet. MoldWizard provides several tools to fill in" missing faces. In the ÏÏÏ
following activity you will use Planar Patch, a Solid Patch Up method.
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Tolerance

The first control in the Tools dialog is Tolerance. For surface patching,
extruding, and splitting tools, this value is used the same way as the modeling
tolerance found under Preferences → Modeling. The Tolerance value will be
reset to the current modeling tolerance if you exit the Tools dialog then activate
it again.

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All Rights Reserved Student Manual 3-9
Parting Preparation

Allow Non-Associative

Enabling the Allow Non-Associative button results in a trade off where file
sizes are reduced in exchange for the loss of full associativity with the original
part model. There may be times when such a trade off is desired or required
due to system limitations. Enabling this button will change the functionality of
some MoldWizard processes. Significant changes in functionality will be noted
where appropriate. The default setting for this button is OFF in order to
maintain full associativity.

Solid Patch Up
The Solid Patch Up section of the tools dialog has two functions, Solid Patch,

ÏÏÏ
which we will discuss later, and Planar Patch.

ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Planar Patch

Planar Patch is an extruded solid patch, hence it is found in the Solid Patch Up
section of the Tools dialog. Planar Patch is used to create a thin skin over
interior holes fully contained in a planar face. Only planar faces with holes are
selectable.

The system detects all closed loops in the face as holes. You have the
opportunity to deselect edge loops that you want to remain open. Be careful
here. Loops around raised features and blind holes are detected. The system
creates a very thin solid extrusion using the outer boundary to form a patch.
Loops that are deselected are used as interior boundaries in the extruded face,
thus blind holes will remain open if their edge loop is deselected.

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Parting Preparation

The advantage of Planar Patch is that it works directly on edge loops, requiring
almost no extra memory. Surface Patch will make one copy of each surface
being patched for each hole. There is a trade off between model size of the
parting part and a .0005 inch gap between shut off faces.

The thickness of the patch sheet can be edited, but it is not recommended to
attempt to use a thickness less than the modeling tolerance. For zero thickness,
use a Surface Patch instead.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

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All Rights Reserved Student Manual 3-11
Parting Preparation

Activity 3-2: Planar Patches

The mdp_cup3 plastic drinking cup model has several holes. In this activity and
the next, you will use Planar Patch, Surface Patch, Edge Patch, and Patch Body
to practice the procedure for each function.

Step 1 Create a product tooling assembly for mdp_cup3.

 If other parts are open, you must close them now.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

First Part .../cup3/mdp_cup3


Units default (Inch)
Proj Name default (mdp_cup3)
Mold Csys default
Shrinkage Scale Factor 1.008

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3-12 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Parting Preparation

Step 2 Create a Planar Patch.

 Choose the Tools icon:

NOTE Choosing Tools changes the current Displayed Part and


Work Part to your parting part if the top level, prod, or
layout part was displayed, but not if other components
were displayed. This intelligence" gives you the
convenience of automatically changing the display to the
parting part when it is desirable, while permitting you to
use the functionality of Tools in other files without
hindrance.

 Choose Planar Patch.


Notice that only the planar faces at the bottom" of the cup
prehighlight as you move the cursor. Only planar faces with
holes are selectable. MoldWizard masks faces that are not valid
for the current operation, making it easier to select the objects
ÏÏÏ
you want.
ÏÏÏ
 Select the bottom" planar face and confirm if necessary. ÏÏÏ
3
ÏÏÏ

The two holes that pass through the bottom" of the cup are
highlighted. MoldWizard reduces the effort you need to
complete the task by detecting loops and selecting them for you.
The selection dialog allows you to select or deselect closed loops
within the chosen planar face.

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Parting Preparation

 Choose OK to accept the two holes the system selected


automatically.

How Does it Work?


As you create a Planar Patch the Status line reads Creating
Extrusion Feature." A Planar Patch is an extrusion of the edge
loop of the planar face. This is why planar patch is located
under the Solid Patch Up section of the Tools menu.

 Cancel the Select Planar Face dialog and the Tools dialog.

 From the menu bar choose Application → Modeling.

 Choose View → Model Navigator, or choose the icon:

 Move the cursor over the second to the last line. This is the
EXTRUDED(#) feature that was just created. Double click
to edit the feature.
ÏÏÏ
ÏÏÏ From the dialog choose Feature Parameters.
ÏÏÏ

3
ÏÏÏ Notice that the extrusion distance is 0.0005 inches.

TIP
You can edit the extrusion distance to whatever
value you prefer by editing the feature parameters.
It is good practice to maintain a thickness that is
greater than the modeling tolerance.

 Cancel the Edit Parameters dialog and the Model Navigator


window.

Step 3 Save all parts, but do not close!

 From the Menu Bar choose File  Save All.

This concludes activity 3-2.

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3-14 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Parting Preparation

MoldWizard Tools Dialog (continued)

Sheet Patch Up

The Sheet Patch Up family of buttons appear at the bottom of the MoldWizard
Tools dialog as shown below:

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Surface Patch

Surface Patch is probably the easiest to use patching method. Surface Patch is
used for holes fully contained within a single face. Choosing the Surface Patch
button opens a Select Face dialog. When a face containing holes is selected, the
system 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.

Although Surface Patch and Planar Patch might be considered equally easy to
use, Surface Patch will usually add more features to your model than Planar
Patch. In Surface Patch, MoldWizard extracts a copy of the underlying face for
each selected hole, then trims the copy to the hole edges.

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All Rights Reserved Student Manual 3-15
Parting Preparation

Edge Patch

ÏÏÏ If holes cross face boundaries, or if a boundary must be created from non

ÏÏÏ contiguous edges, edge patch is useful. With Edge Patch, the user is

ÏÏÏ
3 interactively guided to select edges and curves that define the boundary of the

ÏÏÏ
patch to be created. Choosing the Edge Patch button will open the following
Curve/Edge Selection dialog:

Once the first edge is selected, MoldWizard highlights the Current Path it
believes to be the logical path to follow. As the user, you will respond to the
suggested Current Path using the Curve/Edge Selection dialog shown above.

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Parting Preparation

Accept
Choosing the Accept button will accept the Current Path suggested by
MoldWizard. Note that choosing Accept is not the same as choosing OK. Accept
only confirms the curves in the current path , allowing the system to focus on
finding the next curve.

Next Path
The Next Path button, will as the name implies, suggest and alternate branching
path from two or more possibilities.

Back Traverse
This option will appear when a second edge or curve is selected. Choosing this
button allows you to go back and correct an earlier selected branch.

Close Loop
This button will create a connecting line between the open end point of the first
edge selected and the open end point of the current path edge or curve.

Exit Loop
This button indicates that you have finished your selection and signals
MoldWizard to begin generating a patch based on the geometry selected.
ÏÏÏ
ÏÏÏ
It is not necessary to accept edges offered by the system. All curves and edges
are selectable. In some cases, where curves or edges from multiple bodies have ÏÏÏ
3
ÏÏÏ
been chosen, the system may not determine a current path. If this occurs just
select the next edge you want. If you choose an edge that is not contiguous with
the current patch, MoldWizard will offer the Bridge Gap dialog.

Bridge Gap
When non contiguous edges or curves are selected, MoldWizard will display the
following dialog:

If you click on Yes, MoldWizard will bridge the gap with a line. MoldWizard will
enlarge and trim the created patch surfaces to the boundary.

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Parting Preparation

Existing Surface

ÏÏÏ MoldWizard recognizes that there may be times when the automated features

ÏÏÏ of Sheet Patch Up are not suited for a particular application. One instance

ÏÏÏ
3 where this is likely to occur is when you are working with imported file formats

ÏÏÏ
such as IGES, Parasolid, etc.

When the conventional methods of surface patching are not successful, you may
create the surface patch manually using Free Form features or other
Unigraphics functions. Once created, you can return to the Tools dialog and
choose Existing Surface, where you will then be prompted to select the surface
you created (or another existing surface you may wish to use) for Sheet Patch
Up. The system will make copies of the sheet for both core and cavity trim.

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Parting Preparation

Auto Hole Patch

Auto Hole Patch can automatically patch up all through holes in the product
using a surface based patch method.

When Auto Patch is selected, the Patch Loops Selection dialog will open and
detected open loops will highlight.

1. Select a Patch Method.

2. Select Auto Patch to


create the patch surface.

ÏÏÏ
ÏÏÏ
Patch Method
ÏÏÏ
3
ÏÏÏ
Patch Method refers to where the patch will be applied: the Cavity Side or the
Core Side.

When multiple loops requiring different patch methods are detected; or, if
some of the detected loops do not require patching, the One by One Method
should be employed to address each loop individually.

Selecting the One by One method will open the following dialog:

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All Rights Reserved Student Manual 3-19
Parting Preparation

The One by One method will cause hole edge loops to highlight individually.
Three options are then provided for each highlighted loop:

Patching: This option will cause the system to analyze the detected hole for
draft and other attributes, then apply a patch to the side it deems appropriate.

Skip: This option will simply skip the highlighted loop and move on to highlight
the next loop. A patch will not be applied to the skipped loop.

Extract: This option will extract curves matching the highlighted loop.
Extracted curves of this type can then be used with other modeling functions to
explicitly create a custom patch body or sheet.

Regardless of the Patch Method specified, MoldWizard will analyze an identified


hole for draft and other attributes and intuitively determine one of two things:

 The side MoldWizard deems to be appropriate for patch placement, based


on analysis to prevent undercuts.
ÏÏÏ
ÏÏÏ OR

ÏÏÏ
3
ÏÏÏ
 Either side could be appropriate for patch placement.

If the specified patch method conflicts with what MoldWizard has determined
to be the correct placement face, the specified method will be ignored.

If MoldWizard determines that either side could be patched, the specified


method will be honored.

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Parting Preparation

In this example, MoldWizard will place the patch on the core side regardless of the
Patch Method specified. To do otherwise would result in an undercut or mold lock
condition.

CAVITY SIDE

CORE SIDE
Patch Placement

ÏÏÏ
Working Around MoldWizard's Intuition ÏÏÏ
A wide variety tools are made available for creating patch surfaces and patch
ÏÏÏ
3
ÏÏÏ
bodies.

In cases where an undercut is indeed an intended design feature, patch surfaces


and bodies can be created using patching tools other than Auto Patch.

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Parting Preparation

Activity 3-3: Surface and Edge Patches

Continue to work with your mdp_cup3 project.

NOTE In a few minutes you will retrieve the parting part as it is


now. If you did not save at the end of the last activity,
Save All now.

NOTE Please do not save after this, until instructed to do so!

Step 1 Only if needed, a staged assembly for this activity is in:


.../ moldwizd/ cup3_2 /

ÏÏÏ Procedure to open the staged assembly, if needed:


ÏÏÏ
ÏÏÏ
3
ÏÏÏ



Verify that no parts are open.
Verify that Application  MoldWizard is active.
 Open mdp_cup3_top in .../moldwizd/cup3_2

Step 2 Patch holes in the conical face.


The following two steps are done to learn how the Patch Surface
feature works. Don't worry about the geometry configuration.
We will take care of some problems in a few minutes.

 If necessary, choose Tools:

 Choose Surface Patch.

As you move the cursor over the graphics window, observe that
only faces with interior holes prehighlight. The planar face with
holes that you did not patch earlier is also selectable. Unlike
Planar Patch, Surface Patch creates sheet bodies.

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Parting Preparation

 Select and confirm the outer face of the cup".

A Select Holes dialog appears. Detected holes are pre-selected.

 Choose OK in the Select Holes dialog.

In a second or two, patch sheets are created.

 Cancel the Select Face dialog and the Tools dialog.

How Does it Work?

The system extracts a sheet body, the same as you would obtain
using the tool Enlarge Surface. This sheet is the parent for one
or more patch sheets, one for each hole being patched.

Creating a patch skin over the holes is sufficient to allow MoldWizard


to calculate core and cavity regions; however, simply patching the ÏÏÏ
holes with the easiest method may not meet engineering design intent
ÏÏÏ
for useful tooling.
ÏÏÏ
3
ÏÏÏ
The holes through the conical faces are patched, but a volume of
material will be left in the core area that will not permit removal of the
plastic.

This part requires sliders" or draws", movable pieces of the mold


that form the holes during injection and are withdrawn before the
product is ejected.

In the following steps you will revert to the previously saved parting
body, and patch the two conical faces of the cup with solid bodies that
can be incorporated into slides.

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All Rights Reserved Student Manual 3-23
Parting Preparation

Step 3 Reopen your parting part.

 Choose File → Close → Reopen Selected Parts.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ Á

 Select your mdp_cup3_parting part from the list box.

 Enable Force reopen if modified.

 Choose OK.

 Dismiss the reopen information window.

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Parting Preparation

Step 4 Patch the hole through multiple faces using Edge Patch.

 Zoom in on the hole passing through the cone and bottom


faces, as shown in the figure below:

Reopen the Tools dialog and choose Edge Patch.


ÏÏÏ


ÏÏÏ
ÏÏÏ
 Select edge À as shown in the figure. 3
 Use the controls in the Curve/Edge Selection dialog to guide ÏÏÏ
the system to selecting the edges shown in the figure until
the loop is closed.

When the loop is closed, the system displays an Add or remove


faces dialog. The status line reads Found 3 faces to patch up."

 Choose OK to accept the highlighted faces.

 Cancel the Tools dialog.

Note: Shading the part will display the patch just created.

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All Rights Reserved Student Manual 3-25
Parting Preparation

How Does it Work?

Internally, MoldWizard creates a linked face and a scale feature


for every one of the selected faces. The linked faces point to the
original product model, hence the same scale used for the
shrink part is applied to each linked face. These new features
are bundled together in a feature set named patch_set.
The original part must be open for this process to work properly.
Be careful about using edge patch in an assembly that was
reopened from the disk. The original part is represented by its
empty reference set, and will not be opened.

Creating linked bodies and updating of the original model with


link information takes measurable time. In this part, the time is
negligible; however, in larger parts the delay can be significant.
A user default is provided to set a maximum number of features
in the original part. Beyond this maximum, edge patch will use
an alternative curve mesh approach for Edge Patch:

ÏÏÏ MW_ToolsPatchFeatureNum: 150


ÏÏÏ
ÏÏÏ
3
ÏÏÏ
The linked faces are sewn into a single sheet. The sewn sheet is
then trimmed to the edge loop selected for the patch.

If the patch can not succeed by the method described above,


and the loop consists of a single curve, MoldWizard might create
a PATCH_THRU_CURVE_MESH feature. This behavior may
be turned on or off in the mold_defaults file by:
MW_PartingMeshSurf
Sometimes a PATCH_THRU_CURVE_MESH will be perfectly
acceptable. At other times, you may wish to model a new sheet
and use EXISTING SURFACE to complete the patch.

Step 5 Save your work, but do not close any parts.

 Choose File  Save All.

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Parting Preparation

NOTE Warning Message


The original product part is modified" by extracting sheets. If
that part is read only, you will receive a message when you save
all parts, informing you that although the overall operation was
successful, one part failed to save.
It is not good practice to ignore warnings and error messages
unless you are confident that you understand the situation and
can deal with the consequences.
The set up instructions for your classroom request that all your
parts are read / write; however, work situations will arise when
the original part is read only. At many companies, original parts
are read only to prevent accidental changes by any one user.
It does not matter if modified original parts are not saved. You
can dismiss and ignore warnings about original product models
only.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 If necessary, dismiss the above warning by choosing OK.

NOTE If your classroom is set up properly, you will not see the
above warning. If the warning does appear, please inform
your instructor.

NOTE You will continue to use this project in the next activity.

This concludes Activity 3-3.

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All Rights Reserved Student Manual 3-27
Parting Preparation

MoldWizard Tools Dialog (continued)

Create Patch Block

The Create Patch Block section of the tools dialog contains only one button,
used to create an associative body that can be used as a solid patch, described
later.

ÏÏÏ Create Box


ÏÏÏ
ÏÏÏ
3
ÏÏÏ
A patch block is a good way to complete a parting shape for a local area that is
not suitable for surface patch or edge patch, two methods that are discussed in
the following paragraphs. The patch block is also a good way to create geometry
for slides.

Creating a patch block accomplishes the first two steps of a five step process:

 Define a suitable allowance for trim or draft.

 Select faces to define the block volume


The system will build a bounding box" around the faces you
select, leaving the Allowance amount as extra stock" around
the minimum box that could contain the surfaces.

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Parting Preparation

 Trim the patch block to fit the volume you wish to patch.
 Apply the patch using the solid patch option on the Tools menu. This
step fills in openings between the core and cavity regions, but in most
cases, other faces are also removed.
 Later, locate an automatically linked copy of the patch solid and use a
boolean operation to complete your tooling. This action is necessary to
replace product faces and edges that were removed from the tooling
by the previous step.

The system creates a solid block within a volume you define by selecting
(roughly) bounding geometry. The Allowance value determines how much
larger the block will extend beyond the volume you select. The tool dialog
provides several methods to shape this block to make a plug" for holes.

A toggle controls whether non associative methods are available. As noted


previously, non-associative methods gain an advantage in disk and RAM
Memory requirements by sacrificing associative update capability. The initial
setting of the toggle is controlled in the mold_defaults file.

The block must be trimmed, applied, and later compensated as outlined above. ÏÏÏ
An activity will clarify the use of patch blocks.
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Surface Split

Surface Split, found in the Tools dialog under Split Method, may be used to
shape a patch body to match part contours. In associative mode a combination
of Extract Body and Trim is used; in non-associative mode Split is used.

If the selected face is planar a datum is created and used to trim. If the face is
non-planar a copy is extracted, and the copy is used to trim.

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All Rights Reserved Student Manual 3-29
Parting Preparation

When a copy is extracted it is initially only a small amount larger than the
original face. If the system detects that the enlarged face is not big enough to
perform trim, a second dialog (shown above) is presented offering additional
enlargement tangent to the edge of the original face, up to 900%. If this is still
not large enough to successfully trim, you can use the Enlarge Surface function
(described later) and split or trim manually.

Solid Patch Up

We have already examined Planar Patch and previewed Solid Patch. Solid
Patch is often used when geometry is too complex to trim, or when trimming
functions are simply too time consuming.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Solid Patch

The system guides you to select a target solid (your parting body) and a tool
solid. We refer to the tool body as a patch block, typically but not necessarily
created using Create Box.

Unlike patch sheets, which have no volume, a solid patch changes the shape of
the parting body and one of the mold regions. After parting, core, and cavity
creation a copy of the same solid patch material must be united or subtracted to
compensate for the effect of the patch body. The system provides a linked copy
of patch blocks. It is necessary to manually" perform the required boolean
operation in the appropriate part.

When using solid patch, be very careful not to create internal empty volumes
inside the part. The geometry of internal empty volumes will not appear in any
piece of tooling.

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Parting Preparation

Activity 3-4: Patch Blocks

Continue to use your mdp_cup3_parting part.

Step 1 Only if needed, a staged assembly for this activity is in:


.../ moldwizd/ cup3_3 /
Procedure to open the staged assembly, if needed:
 Verify that no parts are open.
 Verify that Application  MoldWizard is active.
 Open mdp_cup3_top in .../moldwizd/cup3_3

Step 2 Create a patch block for the small circular opening in the
ÏÏÏ
conical wall of the cup.
ÏÏÏ
 If necessary, choose Tools. ÏÏÏ
3
ÏÏÏ
 Choose Create Box.

 In the Create Box dialog:

Type:
Allowance . . . . . . . . . . 0.125

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All Rights Reserved Student Manual 3-31
Parting Preparation

 Select and confirm the cylindrical face of the small hole.

OK is not active until you have selected at least one face.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ  Choose OK to indicate you are finished selecting faces.

A block is created encompassing the volume of the face you


selected.

Step 3 Trim the block to exactly fill the hole.

 Choose Surface Split from the Tools dialog.

 Select and confirm the new block.

The Cue reads Select a surface to split the solid."

 Select the same cylindrical face as you did in the previous


step where you defined the block.

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Parting Preparation

 If the Normal Indicator (N) points away from the volume


you want to keep (inside the hole), choose Trim or OK.

If the indicator arrow were pointing the wrong way you would
choose Flip Trim".
The cue line prompts again for a surface to split the solid.
ÏÏÏ
 Select and confirm the outer conical face of the cup.
ÏÏÏ
Again, the indicator should be pointing in the correct direction. ÏÏÏ
3
ÏÏÏ
 Choose OK to trim the side indicated.

 Select and confirm the inner conical face of the cup.

This time the indicator should be pointing outward, the wrong


direction.

 Choose Flip Trim to remove extra material inside the cup.

 Choose Cancel to exit from the Surface Split operation.


Note: Shading the view will make the solid visible.
How Does it Work?
Create Box creates a UDO (user defined object) and a sweep
feature. Users of earlier releases of MoldWizard would have
observed a single block feature. The UDO and sweep
combination provides full associativity between the patch block
and the faces selected.

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All Rights Reserved Student Manual 3-33
Parting Preparation

Surface Split trim sheets are created in Layer 255, or whatever


is designated as MW_HideObjectLayer in the mold_defaults file.

TIP Avoid making MW_HideObjectLayer visible or


selectable. MoldWizard places certain objects that
are displayed temporarily into the layer designated
by the MW_HideObjectLayer setting.

Step 4 Patch the remaining rectangular opening.

 In the MoldWizard Tools dialog choose Create Box.

TIP When you use Create Box:


 Be careful to pick enough faces to define
the volume you want. Two faces are
ÏÏÏ sometimes enough; occasionally only one
ÏÏÏ is required.

ÏÏÏ
3
ÏÏÏ
 Be careful to pick any faces for which
associative update is desirable!
 The system will create a block oriented
to the ACS that encloses the faces you
select.
 Extra" volume is determined by the
Tolerance setting in the Tools dialog.

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Parting Preparation

 Select and confirm the upper and lower faces, as shown


below, in the upper rectangular opening.

In the current example, the side faces do not sufficiently define


the volume required, due to the curvature of the cup wall.

ÏÏÏ
ÏÏÏ
 Again type Allowance . . . . . . . 0.125
ÏÏÏ
3
ÏÏÏ
 Choose OK.

 Choose Surface Split.

 Select and confirm the new block as the solid to be split.

 One by one, select and accept six trim sheets:

 the four sides of the opening


 the inner and outer faces of the cup.

NOTE Remember to choose Flip Trim where necessary!

 Choose Cancel when the block is fully trimmed.

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Parting Preparation

Step 5 Create Solid Patches.

 Choose Solid Patch in the MoldWizard Tools dialog.

 Select the cup body as the target solid.

 Select first one, then the other patch block as a tool solid.

 Choose OK after you select both patch blocks.

 Cancel the MoldWizard Tools dialog.

How Does it Work?

As you select each tool solid, the system:


 moves the body into MW_PartingPatchBodyLayer (25)
 creates an extract body
ÏÏÏ
ÏÏÏ  unites the extracted body to the target solid

ÏÏÏ
3
ÏÏÏ
If the product model changes, trim sheets update the original
body. Then, extracted bodies update. The extracted bodies are
united to the parting body, so it too updates.
It is up to you, the tool designer, to use an appropriate Boolean
operation to compensate for geometry removed from the
product model by Solid Patch.
At a later step in the process the MoldWizard system will place a
WAVE linked body" for each tool solid into the
MW_PartingPatchBodyLayer in both core and cavity parts. This
automatic linking makes it easy for you to compensate the
material volume associatively. Typically, you will unite the copies
to a tooling body in your choice of the core or cavity part.

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Parting Preparation

Step 6 Save your work.

 From the Menu Bar choose File  Close  Save All and
Close.

 If necessary, dismiss the above warning by choosing Close


Part.
ÏÏÏ
ÏÏÏ
NOTE If your classroom is set up properly, you will not see the ÏÏÏ
3
ÏÏÏ
above warning. If the warning does appear, please inform
your instructor.

This concludes Activity 3-4.

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All Rights Reserved Student Manual 3-37
Parting Preparation

MoldWizard Tools Dialog (continued)

Split Method

The Split Method section of the dialog contains several tools, aside from
Surface Split, which we covered earlier, to divide or trim a body. As with other
operations, full associativity is the default.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Solid Parting

In cases where it is difficult or cumbersome to use surface trim parting


methods, Solid Parting is used. You must first define work piece dimensions
using the Work Piece icon on the MoldWizard tool bar. The shrinkage part will
be subtracted from a linked copy of the work piece. Choose a Split Method to
divide the body into core and cavity sections.

Another immediate effect of choosing Solid Parting is to remove core and


cavity components from the product assembly.

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Parting Preparation

Subtract

Frequently the contours of the part require many trim operations to shape a
patch block. At times, the contours are too complex for trim to be an effective
option. In such cases, one Subtract will produce the correct shape.

The MoldWizard Subtract function is similar to the UG Subtract function,


except that the tool solid is retained after the operation. The system asks you to
pick a target body, usually your patch block, and a tool, usually the shrink
model. In associative mode, the system extracts a copy of the tool solid and
subtracts the copy from the tool. In non-associative mode, the system creates
interference bodies between the target and tool, and subtracts the result from
the target.

Solid Split

Solid Split is very useful to break out" a section of the part that will be a
moving piece in the tooling. It creates the interference solid(s) between a target
and a tool body, and subtracts the tool volume from the target solid. ÏÏÏ
ÏÏÏ
In associative mode the operation is performed with extracted bodies. In
non-associative mode every resulting body will be an unparameterized
ÏÏÏ
3
ÏÏÏ
feature.

Split

Split asks the user to select a target solid and a tool sheet or datum.

In associative mode the system uses extract body to make a second copy of a
target solid. The tool sheet or datum is then used to trim both bodies, each on
opposite sides of the trim object. The tools sheet and both trimmed bodies
remain and are associative.

In non-associative mode the splitting face is used to divide the target body into
two unparameterized features. The splitting face is removed from the model in
this mode.

A datum plane can be used to split a solid only in associative mode.

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All Rights Reserved Student Manual 3-39
Parting Preparation

Profile Split

A target body is split using an extruded closed profile. You will be prompted to
select curves or edges to extrude. Choices are added to the options in the dialog
with the first and second picks. By the third pick, the dialog appears as shown:

The vector subfunction is presented to determine the extrude direction.


ÏÏÏ
ÏÏÏ Finally, a dialog is presented to set extrude distances:
ÏÏÏ
3
ÏÏÏ

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Parting Preparation

Activity 3-5: Solid Patch Compensation in the Tool

This part:

 demonstrates the Subtract tool


 previews the procedure to unite a linked patch body in core or cavity
to compensate for geometry removed by Solid Patch

Step 1 Create a project for mdp_cap.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

First Part .../cap/mdp_cap


Units default (Inch)
Proj Name default (mdp_cap)
Mold Csys default
Shrinkage Scale Factor 1.008
Work Piece default
Layout Auto Center

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All Rights Reserved Student Manual 3-41
Parting Preparation

Step 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 tedious to repeat
the face confirmation process twelve times.
In this case, Solid Patch is an efficient method to use.

 Choose Tools.

 Choose Create Box.

 Use the default value for Allowance. (Ignore the Allowance


text input window.)

 Select, and confirm if necessary:


ÏÏÏ
ÏÏÏ  the inner face containing the window openings . . . À
ÏÏÏ
3
ÏÏÏ
 the small inner face nearest the top of the cap . . . . Á

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Parting Preparation

 Choose OK to end selection.

A block is created surrounding the material volume defined by


the faces you selected.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
The patch block can be trimmed in one or two areas, but there
are several concentric faces with opposing directions.
With multiple faces and complex geometry it is a lot faster to
use a Boolean subtract to shape the patch body using Subtract
in the Split Method section of the Tools dialog.
The current topology presents a problem. A Subtract at this
stage would divide the patch block into more than one piece.
When Subtract divides a body into multiple pieces, it causes all
parameters to be removed. In our scenario, we specify full
associativity, thus, we need an approach that retains parameters.
We can avoid trouble by trimming the rectangular patch body to
the largest inside diameter of the part before we subtract.

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Parting Preparation

Step 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 enlarge sheet dialog appears.

 Do NOT change U.

 Expand in the V direction to approximately 400%, until the


cone extends past both ends of the block.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Choose OK to accept the UV values and trim the patch


body.

 Cancel to return to the Tools dialog.

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Parting Preparation

Step 4 Use Subtract to complete the patch body.

 From Tools, in the Split Method section, choose Subtract.

NOTE The order of selection is very important. Watch the Cue!

 Select and confirm the smaller, green patch body as target.

 Choose the larger, cyan parting body as tool.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

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Parting Preparation

Step 5 Use the patch body to create shut off faces in the
windows.
 Choose Solid Patch.

 Select the larger, outer pen cap body as target solid, and the
smaller interior 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.
MoldWizard 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.
The following steps give you a preview of the actions necessary to
replace the missing faces in the core workpiece. This will help you to

ÏÏÏ
fully understand what you accomplish by uniting a patch body.

ÏÏÏ
ÏÏÏ
3
ÏÏÏ
Step 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 . . À

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Parting Preparation

MoldWizard identifies the correct parting loop . . . Á

Once the parting loop has been identified, the Product Design
Advisor becomes available.
Auto Patch remains grayed out, an indication that Solid Patch

ÏÏÏ
successfully removed all holes from the part.

ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Choose Product Design Advisor . . Â

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All Rights Reserved Student Manual 3-47
Parting Preparation

Product Design Advisor tells you at a glance that there are no


vertical faces, one potential undercut area, and 65 Small Angle
Faces with a Draft Angle less than 3°.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Choose the Undercut Areas radio button to verify what the


system has found.
The bottom face of the patch body, remaining after Solid Patch,
is highlighted. In wireframe mode, you might be able to discover
a reason for such a face being highlighted, perhaps a small gap
caused by tolerance issues. There will be no problem with this
part; however, it shows the value of the Product Design Advisor
as a diagnostic tool.
 Choose the Small Angle Faces radio button to highlight faces
with draft angles less than the value in the Draft Angle <
window.
Almost every face on the Cavity side highlights.

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Parting Preparation

We know there are no Vertical Faces, because that radio button


remains grayed. We can use the Product Design Advisor to
quickly investigate the minimum draft on the product.

 In the Draft Angle < window, enter: 1.000

 Choose Apply.

À Type a value

Interpret the result

ÏÏÏ
 ÏÏÏ
ÏÏÏ
3
ÏÏÏ

Á
Apply the change

Small Angle Faces now displays 25 faces, 24 faces between the


ribs" and one small conical face at the top of the part.

 Change the Draft Angle < value to 0.5, Apply, then choose
Small Angle Faces once again.

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Parting Preparation

The small face at the top is no longer highlighted. It is drafted at


least half a degree.

 Change Draft Angle < to 0.49

Small Angle Faces are no longer found. The part has


approximately 0.5° draft, within .01 degrees!

 Choose OK to exit the Product Design Advisor.

 Choose OK in the Search Parting Lines dialog to accept the


previously identified parting loop. (It is no longer
highlighted.)

NOTE The parting curve (only one arc in this case) is displayed,
colored green. The green color indicates that while
geometry has been chosen, the process is still incomplete.
It is important not to dismiss the Parting Lines dialog by
Cancel, or the system will not correctly identify your
ÏÏÏ parting curve(s).
ÏÏÏ
ÏÏÏ
3
ÏÏÏ  Choose OK in the Parting Lines dialog.

How Does it Work?

The parting curve should now change to a magenta color, and


the Create Parting Surfaces dialog appears.
This magenta color was selected for class. The default color is
green, the same as the default curve creation color. We edited
our defaults file to make it easier to realize when the operation
has been successfully completed, and, to recognize if it was not
successfully completed.
The Create Parting Surfaces dialog appears now because you
selected Auto Process.
When you first create potential parting curves, they are placed
in a named group, UM_EXTRACT_CURVES. This enables the
system to easily relocate curves to MW_HideObjectLayer.

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Parting Preparation

We will deal with the full set of choices that complete the
identification of parting curves in a later lesson. At this point,
you need to understand only that when you choose OK the
process is completed properly. The arc you selected is moved to
MW_PartingLinesLayer (26), category PartingLine
(MW_PartingLinesLayerName). Additionally the curve is colored
MW_PartingLinesColor (magenta for the class) and added to a
special group, UM_PARTING_LINES. The parting lines group
is used when you create parting surfaces.

Step 7 Create the parting surface.

 Enter 8.0 in the Distance window.

ÏÏÏ
ÏÏÏ
Á ÏÏÏ
3
ÏÏÏ

 Choose Create Parting Surfaces.

A Warning Message appears:

 Choose OK to create a single parting surface.

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Parting Preparation

Step 8 Define Core and Cavity regions.


Extract Regions appears because you selected Auto Process.

Parting Face

 Fit the view to see the parting face.

The Extract Regions dialog is equipped with sliders to permit


you to examine faces that MoldWizard has automatically
determined belong to core and cavity tooling. We will study the
ÏÏÏ features of this dialog more completely in a later lesson.
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

 Use the sliders to preview the cavity and core 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.

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Parting Preparation

Step 9 Complete the core and cavity bodies.


The Core & Cavity dialog appears because of Auto Process.

0.0004

We will learn the features of this dialog in a later lesson.


 From the Core & Cavity dialog choose Create Core . . . À
ÏÏÏ
ÏÏÏ
The Select Sheets dialog appears:
ÏÏÏ
3
ÏÏÏ

 In the Select Sheets dialog choose OK.


The View Parting Result dialog appears. The displayed part has
been temporarily changed to mdp_cap_core. As with the other
dialogs in this process, we will learn more later.

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Parting Preparation

 Examine the body that was created as your core tool insert.

 Choose OK in the View Parting Result dialog to return to the


parting part.

The layer settings in the parting part were changed. The


geometry you see now represents a sewn core trim sheet
containing the parting sheet, the core region, and a seed face".
ÏÏÏ
ÏÏÏ How Does it Work?
ÏÏÏ
3
ÏÏÏ The parting sheet and seed face are mutually trimmed. The seed
face is oriented perpendicular to the main parting plane. This
face has been in the part from the time you initiated the project.
Its purpose is to act as the linking geometry between the parting
part and the core tool. A similar face exists for the cavity tool.
The vertical orientation of seed faces is a clever trick to be
certain that they can be joined to your parting geometry no
matter where in vertical space you might choose to locate them.

 Make layer 1 the Work Layer, and optionally make layer 27


Invisible.

Step 10 Compensate for geometry removed by Solid Patch.

 Window to mdp_cap_core.

 Make layer 25 Selectable.

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Parting Preparation

The missing faces appear. You are seeing a Wave linked body
that MoldWizard has automatically created and associated to
the original patch block you created.

Linked patch body

Core work piece

 If necessary choose Application → Modeling.

 Unite the two bodies:

 Select the larger, lower, core body as the target.

ÏÏÏ
ÏÏÏ
 Select the smaller, upper, green linked body as the tool.

This completes the plan you made to compensate for faces


ÏÏÏ
3
ÏÏÏ
removed from the parting part by the patch body.
The core section is well suited to machine with a lathe. In a later
lesson you will learn how to create a sub insert in a work piece.
You may then, on your own, choose to return to this project to
design an appropriate sub insert.

Step 11 Save your work.

 From the Menu Bar choose File  Close  Save All and
Close.

This concludes Activity 3-5.

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Parting Preparation

MoldWizard Tools Dialog (continued)

Sheet Patch Up (continued)

There is one function under Sheet Patch up we have not examined, Enlarge
Surface.

Enlarge Surface

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

The enlarge surface function is useful for trim operations in patch up work.
Enlarge Surface features can be edited using feature edit beyond the 900%
maximum value of the slide controls. Another common use 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 to adjust an enlarged face to workpiece boundaries.

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Parting Preparation

The system prompts you to pick a face. A copy of the face is created, slightly
larger than the selected face. 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. The dialog shown below appears:

ÏÏÏ
ÏÏÏ
The sliders control the expansion of the face along U and V directions,
ÏÏÏ
3
ÏÏÏ
represented by cone head arrows in the graphics display. You can slide the
surface larger, from 10 to 900 per cent, in either direction. This tool also
appears during the Surface Split operation for trimming a solid patch. The
slider settings are retained as numeric expressions and may be edited using the
Edit Expression dialog.

The Cut to Boundary toggle is used to trim the sheet. The system displays a
point at the negative U negative V corner of the sheet. When Cut to Boundary
is active the Edit Boundary, Add Boundary Face, Keep or Discard, and Edit
Trim Point buttons are available. Edit Boundary allows you to add or remove
trim curves. Add Boundary Faces allows you to select faces as part of the trim
boundary. The Keep and Discard radio buttons refer to the section containing
the displayed point. Edit Trim Point allows you to respecify the location of the
point for keep and discard. The trim operations within this MoldWizard
function are also available in Toolbox → Free Form Feature → Trimmed Sheet.

As Existing Surface is used to automatically identify and copy the surface for
use in core and cavity regions. If this toggle is OFF, the surface is a general free
form sheet.

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Parting Preparation

Activity 3-6: Enlarge Surface

In this activity you will use Enlarge Surface to create a natural parting face.

Step 1 Create a product tooling assembly for mdp_case6.

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ
First Part .../case6/mdp_case6
Units default (Inch)
Proj Name default (mdp_case6)
Mold Csys default
Shrinkage Scale Factor 1.005
Work Piece default
Layout Auto Center

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Parting Preparation

Step 2 Create a parting face.

 Choose Application  Modeling.

This action is only to enable Undo if it is needed later.

TIP If you enter the Modeling application after performing


some MoldWizard operations, the Undo list will be
truncated when you enter modeling.
It is useful, when you think you will want to use modeling
functions, to enter modeling right away after initializing,
so as not to lose any Undo steps.

 Choose MoldWizard Tools.

 Choose Enlarge Surface.


Note: Do not confuse MoldWizard's Enlarge Surface with

ÏÏÏ
Insert  Free Form Feature  Enlarge... The MoldWizard

ÏÏÏ
Enlarge Surface function has several additional options.
 Select and confirm the face shown in the figure below.
ÏÏÏ
3
ÏÏÏ

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Parting Preparation

 Enable the Cut to Boundary toggle.

ÏÏÏ Move the sliders to no more than 1% in U and 10% in V.


ÏÏÏ


ÏÏÏ
3
ÏÏÏ
U and V direction indicators

Trim Point

 When the sliders are adjusted correctly, choose OK to create


the enlarged sheet.

 Cancel from the Tools dialog.

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Parting Preparation

Step 3 Adjust the enlarged surface.

 Make layer 20 Selectable.

 Orient View to Top.

This enables you to see the work piece insert parent body while
you adjust the enlarged face. It is important to be able to judge
when the face is large enough to trim the work piece.
If you did not exceed the suggested UV values, it should be
apparent that the surface just enlarged does not extend
completely beyond the edges of the work piece.
The face is a parametric feature. We can easily edit the U and V
values we entered until it reaches an appropriate size.

 Activate the Model Navigator.

 Double-click on the icon for Patch(19) . . . À

ÏÏÏ
ÏÏÏ
ÏÏÏ
3
ÏÏÏ

The Sets of Features dialog appears.

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Parting Preparation

ÏÏÏ Á
ÏÏÏ
ÏÏÏ
3
ÏÏÏ Â
 Toggle Hide Feature Set Members to OFF (unchecked) . . Á

 Choose OK . . Â

TIP Model features that are positioned, suppressed, or


deleted together may be collected into a single Feature
Set: Format Õ Group Features

MoldWizard makes use of feature sets to maintain a well


organized feature tree.

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Parting Preparation

 Double-click over the icon for Sheet body(15) . . . Ã

ÏÏÏ
ÏÏÏ
The Edit Parameters dialog opens.
ÏÏÏ
3
ÏÏÏ

 Choose Drag . . . Ä

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Parting Preparation

The Percentage Control dialog opens.

Å Æ

 Choose the U option . . Å

ÏÏÏ
ÏÏÏ  Use the slider bar to edit the U Extension Percentage

ÏÏÏ
3
ÏÏÏ
value until the enlarged face is larger than the block,
(Approximately 12-13% in the U).

 Choose the V option . . . Æ

 Use the slider bar to edit the V Extension Percentage value


until the enlarged face is larger than the block,
(Approximately 70% in the V).

 Choose OK.

In the Model Navigator, there is one TRIMMED_SHEET


feature and two EXTRACT_BODY features following the sheet
body. These features are the result of As Existing Surface being
enabled.
MoldWizard automatically placed the extracted copies into the
core and cavity layers, one copy to each of the two layers, and
identified them for future use.

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Parting Preparation

Enlarged Sheet

Insert Block (Work Piece)

Body in Parting Part

With this particular contour the sheet body you created will
create a smooth parting with no steps or discontinuities. If we
ÏÏÏ
use the normal parting method of extruding edges, the results,
ÏÏÏ
while certainly workable, would not be as easy to machine and
maintain as this face. ÏÏÏ
3
ÏÏÏ
In a later lesson you will use this method to complete a parting
trim on core and cavity tooling inserts.

Step 4 Save your work.

 Cancel the Model Navigator window.

 Choose File  Close  Save All and Close.

This concludes Activity 3-6.

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Parting Preparation

SUMMARY MoldWizard provides a versatile range of tools


for creating shut off geometry.

In this lesson you:


 Used the Product Design Advisor to identify
potential problems in a customer supplied"
model.
 Identified holes requiring patch up.
 Used patch Tools to create shut off

ÏÏÏ geometry.

ÏÏÏ  Previewed compensating in a tooling part


ÏÏÏ
3
ÏÏÏ
for faces removed by patch body from the
parting part
 Previewed using the Product Design Advisor.
 Used Enlarge Surface.

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Family Molds and Layout

Family Molds and Layout


Lesson 4

PURPOSE In this lesson you will learn how to manage tooling assemblies
for molds containing two or more identical or related products.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Use Load Product in an existing tooling assembly to


create a family mold.
 Use Layout to arrange work piece inserts.
 Use the Family Mold icon to select a member
product as the target for MoldWizard's utilities.
 Use Layout to create a circular array of mold
inserts.

ÏÏÏ
ÏÏÏ
4
This section contains the following activities:
ÏÏÏ
Activity Page
4-1 Family Mold Project: Toy Shapes . . . . . . . . . . . . . 4-16
4-2 Circular Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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All Rights Reserved Student Manual 4-1
Family Molds and Layout

Family Mold

Related products are commonly formed in a single injection mold. Molds that
produce multiple parts of different designs, such as top and bottom cases of a

MoldWizard automatically arranges Family Mold projects into an assembly


structure with a separate branch for each part. The Family Mold function
allows you to select an active part" from parts that have been loaded in the
family mold for the operations to follow.

MoldWizard functions intended to operate on a specific part or related files are


called part specific operations.

Examples of part specific operations are Shrinkage, Parting, and Mold


Coordinate System. The part that has the focus of attention for various
functions is called the active part.

ÏÏÏ
ÏÏÏ
4 The Select Plastic Product dialog, shown above, appears when you choose the

ÏÏÏ Family Mold icon while a family mold is open. If there is only one product
present, the dialog will not appear and you will get a warning message.
Highlight any product in the list, then choose OK, or simply double click on the
name of product you wish to be active.

NOTE Moldbases and some Standard Parts such as Support


Columns, are installed in assembly branches that are not
part specific. These operations are not affected by which
part model is active.

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Family Molds and Layout

Remove Family Member

The Remove Family Member button found on the Select Plastic Product dialog is
used to remove a product from the family mold. This function will remove all
the assembly components (shrink, parting, core, cavity, etc...) related to the
product removed.

Load Product

If you select Load Product when a MoldWizard top" assembly is already open,
a prod" sub assembly for the new product is created below the layout" node.
This new sub assembly has the standard structure:

ÏÏÏ
Á ÏÏÏ
4
 ÏÏÏ

À The _layout" sub assembly may contain one or more


product sub assemblies.
Á Plastic Products
 Each product has this six part sub-assembly structure.

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Family Molds and Layout

Load Product and Mold CSYS


When a family part is loaded, it will use the Mold CSYS of the currently active
part.
When a product model is positioned/repositioned using the Mold CSYS
function, the transformation information is recorded by MoldWizard and
retained for later use. Any additional product models that are loaded will be
positioned with the same transformations as the model that preceded it.

Matching the transformation is useful for replacing a product model when


associative changes cannot be made. In this process, a new parting set is created
based on the new model. The new parting set can be linked to the cavity and
core models of the original set to maintain downstream work where possible.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Family Molds and Layout

Layout
Family molds or multiple cavity molds include two or more workpiece inserts
within the mold base.
Layout provides tools for easy positioning of multiple workpieces relative to
each other in the mold.

NOTE: Use Load Product exactly once for each product in the mold.
Use Layout to create multiple instances of products.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Within Rectangle configurations inserts may be positioned as Balanced or
Linear. In Circular configurations they may be oriented Radial or Constant.

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Family Molds and Layout

Layout Methods

Automatic Rectangular Layouts

Procedure

 Choose Balance or Linear

ÏÏÏ  Select a number of cavities (2 or 4) . . À

ÏÏÏ
4 Optionally enter offset distances
ÏÏÏ


 Choose Start Layout . . . . . . . . . . . . . Á


 Choose a direction

There are two automatic" rectangular configurations, 2 cavity and 4 cavity.

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Family Molds and Layout

2 Cavity Layout
The workpiece is offset in a user selected direction. If Balance is enabled, the
second instance is rotated 180° from the first.

Inserts may be separated by a gap. The value entered in the 1ST Dist window
governs gap. A zero value means the inserts will touch.

The example below shows two results for a 2 cavity layout. In each case we
selected the vector indicated by the arrow at the left. The result in the center of
the diagram is Linear. The result at the right of the diagram is Balanced. The
same gap, or 1ST Dist., was used for both examples.

Select any one of 4 offset directions

Optional Gap, 1ST Dist.

2 Cavity, Linear 2 Cavity, Balanced

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Family Molds and Layout

4 Cavity Layout
Select the first direction. The second direction is always 90° counterclockwise
from the selected vector, like the Y+ (second) axis to the X+ (first) axis.

Select First Direction ¬ from Four Choices

­
¬
¬ ­
¬ ­ ­ ¬
Second Direction is 90 Counterclockwise from the
direction vector selected

Plus or minus offset distances for gaps or overlaps may be entered.

Balance causes a copy of the insert in the first direction to be flipped", just as
with two cavity. The third and fourth inserts are translated from the first pair.

The original insert is at the upper left corner of the diagram. The downward"
vector is the direction. 1ST Dist is zero, 2ND Dist. is a small positive number.

Offset direction

ÏÏÏ À Â
ÏÏÏ
4
ÏÏÏ
Á Ã
1ST Dist. is Zero

2ND Dist. is a small plus value


Second instance is: Third and Fourth copies are:
– in direction chosen – 90 Deg. CCW from direction chosen
– rotated 180 Deg. (Balanced) – translated with no rotation
– zero gap (1ST Dist.) – gap (2ND Dist.)

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Family Molds and Layout

Circular Layout

Procedure
 Choose Radial or Constant
 Enter Cavity Number, the total number of inserts
 Enter Start Angle from absolute X+
 Enter Rotate Angle for the total angle between all instances
 Enter Radius from absolute (0,0,0) to the reference point on the first
instance
 Choose Start Layout
 Identify a Reference Point

Circular layouts are almost completely user defined. MoldWizard does compute
the angle between individual instances, given a start angle, total angle, and
number of instances.

The Reference Point has to be considered carefully to understand what will


happen. We will give some straightforward examples of arrays where the
reference point is simply Absolute (0,0,0). Examples of the effect of choosing a
different reference point will follow later.

NOTE Circular arrays are always built about the absolute coordinate
system (ACS) of the layout part. When you load new product and
faithfully remember to set the mold coordinate system, the ACS of
the product is transformed to the ACS of the layout part.

Radial and Constant


ÏÏÏ
The Radial option orients components by rotation
ÏÏÏ
4
about the selected center point. The Constant option
maintains the same orientation as the original insert at
each position.
ÏÏÏ
The first instance is always oriented exactly the same as
it was before the array was created, even when a start
angle is specified.

Cavity Number
This is the total number of cavities, including the one
you started with.

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Start Angle
Angle with absolute X+ where the first instance will be positioned.

Rotate Angle
Total angle from the first instance to the last. The system will automatically
calculate the angle between individual instances.

Radius
The distance to move the first instance from the Absolute origin point along the
direction specified by the start angle to the new location of the reference point.

A radial pattern of five inserts, radially located to the center of each insert.

Cavity Number: 5 Á
Start Angle: 0.0°
Rotate Angle: 360°
Reference Point: (0,0,0)
Â
À
360

Before Array
Radius

Ã
ÏÏÏ °
ÏÏÏ
4
ÏÏÏ

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A constant pattern of three inserts over 120°, radially located to the center of
each insert.

Cavity Number: 3
Start Angle: 45° Á
Rotate Angle: 120° À
Reference Point: (0,0,0)
 120

45

Radius
Before Array

Reference Point

The two previous examples use the center of the insert as the point to which the
array is dimensioned. We need to consider a reference point on the part cavity to
which we will dimension our array.

Think of making a drawing of our circular layout of inserts. We have a point on


the cavity (or insert) in mind as the end point of a radius line, where the length
of the line represents the array radius, and the angle of the line with the X+
axis represents the start angle.

The array is always built around the Absolute Origin, rotating with
counterclockwise as the positive direction. How, then, do we control exact
ÏÏÏ
ÏÏÏ
placement of a member of the array? The solution is to select a reference point
4
ÏÏÏ
on the part cavity!

When you select a reference point on the cavity, the system first translates the
cavity and workpiece FROM the reference point TO absolute (0,0). Then, the
cavity is transformed from that location according to the array parameters you
entered.

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Family Molds and Layout

A radial pattern of 6 inserts, radially located about a Reference Point on the


cavity.

Cavity Number: 6
Start Angle: 0.0° Á
Rotate Angle: 360°
Reference Point: Selected as shown Â

À Before Array
À
360

Ã
Á
Selected Reference Point
Radius
is moved to Absolute 0,0

Å
 Array is created °

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Family Molds and Layout

Insert Pocket

When Insert Pocket is chosen, a Standard Parts dialog will appear. The
interaction of this type of dialog is discussed later in the class.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Family Molds and Layout

Reposition Methods

Positioning of one or more inserts can be modified using Reposition functions.

There are three options for manual control over product sub assemblies within
a mold base layout. Rotate, Transform and Remove all operate on whichever
products are selected, or highlighted.

Auto Center automatically repositions the entire layout.

Rotate

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
The Rotate Cavity dialog features Move and Copy radio buttons, a slider control
to dynamically rotate the cavity about a center point, a numeric input window
for exact value entries, and a Set Rotate Center button. Set Rotate Center opens
the Point Subfunction dialog to pick a center point.

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Family Molds and Layout

Transform

The Translate dialog also has Move and Copy radio buttons, and two slider
controls to dynamically position an insert in X or Y. The X and Y input
windows allow precise values to be input. In these windows, and the rotate
input window, use the Enter key to immediately see the effect of your numeric
entry. The From Point To Point button functions in the same manner as all UG
transformations. You pick first at a point you want to move, and second at the
position to which you want the first point to go.

Remove

Remove will remove an instance of the highlighted part from your layout,but
only if there is more than one instance present.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
Auto Center

Auto Center causes the system to automatically position the geometric center of
the current layout, as viewed in the XY plane, to the Absolute (0,0) of the
layout sub assembly. This position corresponds to the center of the mold base,
where the XY plane is the principal parting, and the Z+ axis is the direction
the moving half of the mold travels when opening the mold.

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Family Molds and Layout

Activity 4-1: Family Mold Project: Toy Shapes

In this project you will add several products to a MoldWizard tooling assembly.

mdp_hex

mdp_star
mdp_cir

mdp_sqar

You determine that the family of toys shown above will match an
existing 14x14x2 standard size used at your company if the parts are
formed by four 7x7x2 insert sets. You locate the parting .875 inches
above the bottom of the lower core insert, leaving 1.125 inches for the
cavity Z dimension.

Step 1 Create a new toys" project.

ÏÏÏ First Part .../family/mdp_cir


ÏÏÏ
4
ÏÏÏ Units default (Inch)
Proj Name toys

Step 2 Load a second part.

 Open the Assembly Navigator. Use the Expand All icon or


Tools  Assembly Navigator  Expand All. Size the
Navigator window large enough to observe changes to the
toys_layout sub assembly.

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Family Molds and Layout

 Choose the Load Product icon, filter to the family directory


and choose mdp_sqar.

When you accept mdp_sqar the system does not ask for project
information!
The Assembly Navigator displays a new component: product
subassembly toys_mdp_sqar_prod is created under toys_layout.

Step 3 Create an insert for the currently active part.

 Close the Assembly Navigator, or move it out of your way.

The two products are currently positioned at the same


coordinates. We will create inserts for each, and then line up the
edges of the inserts as shown below:

ÏÏÏ
ÏÏÏ
4
 Choose the Shrinkage icon. ÏÏÏ
The work part changes to toys_mdp_sqar_shrink. The most
recently loaded product is the active part upon which many
MoldWizard 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 the Work Piece icon.

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Family Molds and Layout

The default dimensions X_length and Y_length conveniently


default to 7 inches for the square product, but you need to
adjust the Z_down and Z_up values.

 Adjust the Work Piece Dimensions:


Type:
Z_down . . . . . . . . . . . . 0.875
Z_up . . . . . . . . . . . . . . . 1.125

 Choose OK.
In a few moments the insert appears.

Step 4 Create an insert for the circle part.

Choose the Family Mold icon:


ÏÏÏ


ÏÏÏ
4
ÏÏÏ

The Select Plastic Product dialog appears. Each product in the


top assembly appears in a selection list.

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Family Molds and Layout

 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.

TIP Choose Family Mold at any time to confirm the currently


active product. Change products or simply choose Cancel
to exit the dialog if the current product is the one you
want to work with.

 Enter a shrink value of 1.005, then choose OK.

 Choose the Work Piece icon.

 Again, adjust the Work Piece Dimensions:

Type:
Z_down . . . . . . . . . . . . 0.875
Z_up . . . . . . . . . . . . . . . 1.125

 Choose OK.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Step 5 Position the circle and square inserts.

 Choose the Layout icon:

The Cavity Layout dialog appears:

ÏÏÏ
ÏÏÏ
4
ÏÏÏ
 Fit the view to see clearly where the system has placed both
inserts.

The circle part and insert are highlighted. It does not matter
which part you move. Eventually, you will use Auto Center to
position your entire layout at the mold center.
 Choose Transform in the Cavity Layout dialog . . À

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Family Molds and Layout

The Translate dialog appears.

 Move the sliders, enter values, or use From Point To Point to


reposition the insert.

NOTE The highlighted body shows the current destination" of


the part if you accept the values shown in the dialog.
When using Point to Point ignore the highlighted body.
Choose points on the original, non-highlighted body.

After a brief period of experimentation with the sliders it should


be clear that the correct translation is 7.0 in X and 0.0 in Y. You
can use From Point To Point and simply move a corner of the
insert to the location where it belongs, or, type in values in the X
and Y text input boxes and hit enter to update the position.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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 Choose OK when the inserts are positioned as shown below.

Step 6 Load the remaining toy shape products.

NOTE Make certain all four product inserts are the same size.

 Repeat the preceding steps to load and position the star and
hex parts. Don't forget shrinkage!

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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Your final toy tooling assembly structure should look like this:

Step 7 Center the layout.


 After the last insert is positioned, choose the Layout icon (if
necessary) to open the Cavity Layout dialog.

 Choose Auto Center.


The work pieces are centered as shown in this view of the
trimmed core tooling:

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

Step 8 Save your work.


 Choose File → Close → Save All and Close.

This concludes Activity 4-1.

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Activity 4-2: Circular Layout

In this activity you will again open your hub assembly and create a circular
layout similar to the illustration below.

Step 1 Open your existing product tooling assembly for


mdp_hub.

 Choose File  Recently Opened Parts.

ÏÏÏ Your mdp_hub_top assembly should be on the list. If not, use


ÏÏÏ
4 File  Open.
ÏÏÏ If needed, use this staged assembly instead: moldwizd / hub_2/

 Choose Application  Modeling.

Entering the modeling application now guarantees that Undo


will be available if you need it.

 Make Layers 7 & 8 Selectable.

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Family Molds and Layout

We require the lug" to face the center of the array. The lug currently
lies along YC-; therefore, we want to translate the part along YC+.
XC+ is 0°, thus our Start Angle (measured counterclockwise) is 90°.

We want to move this feature


along YC+, so that it “points
towards” the origin.

The arc centers of the inserts must lie on a 8.0 inch diameter
circle, 6 cavities equally spaced. This dictates 4.0 as the Radius,
and 6 as the Cavity Number.

60 Typ.
∅ 8.000

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

You could calculate the required layout parameters using the


information in the above illustration.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 4-25
Family Molds and Layout

Step 2 Create a circular layout.


 Choose the Layout icon.

 Enable the Circular option. Radial should be enabled by


default.

 Enter the parameters shown in the chart and illustration


below:
Type:
À Cavity Number . . . . . . . . . . . 6
Á Start Angle . . . . . . . . . . . . . . . 90
 Rotate Angle . . . . . . . . . . . . . 360
à Radius . . . . . . . . . . . . . . . . . . 4.0

Á
Â

Ä
ÏÏÏ
ÏÏÏ
4
ÏÏÏ

 When the values are entered, choose Start Layout . . Ä

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4-26 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Family Molds and Layout

The Point Constructor appears.

Since the dimension for the radius is given to the center of the
insert, choose Arc/Ellipse/Sphere Center, and then select either
the upper or lower circular edge of the insert . . À

À ÏÏÏ
ÏÏÏ
4
ÏÏÏ

 Fit the view.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 4-27
Family Molds and Layout

You chose 90 as the Start Angle to set YC+ as the direction that
the part was translated before the array was created.
XC+ is by definition at start angle 0.0°. The angle is measured
counter clockwise, thus YC+ is at 90°.
Rotate Angle is 360° because you want a complete circle of six
inserts. The system calculates the incremental angle between
instances.
As soon as you choose a reference point the system creates the
layout specified.

 Choose Cancel to exit the dialog.

ÏÏÏ
ÏÏÏ
4
 Optionally, Undo your work, and experiment with different

ÏÏÏ circular array parameters. This project is not needed again.

 Please Close all parts when the allotted time for the activity
period has passed.

This concludes Activity 4-2.

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4-28 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Family Molds and Layout

Removing the only instance of a product

The layout function does not provide the ability to remove the only instance of
a product from a MoldWizard assembly.

The following step by step procedure is provided for anyone who is not fully
comfortable with Unigraphics assemblies functionality.

Procedure:

 Make the layout part the work part.


 Close all product related parts using either File  Close  Selected
Parts, or the Assembly Navigator. Related parts consist of the prod"
sub assembly with its shrink, parting, core, cavity, and if necessary, the
original product part.

Removed component parts still open in memory would reappear on


disk after a Save All.
 Remove the prod" component from your Layout sub assembly
 Select the component in the Assembly Navigator
 Choose Edit  Delete
 A warning will appear that component(s) will be removed, but
the parts will not be deleted.
 Remove the prod" part and its child parts from your project directory
manually using your operating system.

ÏÏÏ
Removed component parts that are still present in your project
ÏÏÏ
4
ÏÏÏ
directory can cause future problems if you decide to add the product
again. When you first closed the parts from memory, you prevented
the possibility of them reappearing in your directory due to a Save All.
 Save All.

This saves the assembly structure as modified. If you fail to save after
the above steps, you will get error messages about missing component
parts when you next open your assembly.

If you had failed to close the unwanted parts from memory, they would
reappear in your project directory at this point.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 4-29
Family Molds and Layout

SUMMARY MoldWizard provides useful tools to create and


configure family and multiple cavity molds.
When you have multiple products, only one is
the active product, or, the target for various
MoldWizard functions. When you have multiple
instances of one product, remember to use
Layout rather than Load Product to create
additional instances.

In this lesson you:


 Used Load Product in an existing tooling
assembly to create a family mold.
 Used Layout to arrange related work piece
inserts.
 Used the Family Mold icon to select a
member product as the target for
MoldWizard's utilities.
 Created a circular layout.

ÏÏÏ
ÏÏÏ
4
ÏÏÏ

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4-30 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Core and Cavity Definition

Core and Cavity Definition


Lesson 5

PURPOSE You will learn how to identify or create parting geometry and
define the regions of your part model to be formed by core or
cavity tooling. You will complete the topic by creating associative
tooling bodies, including sub inserts.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Identify parting edges and curves.


 Identify transition objects.
 Construct and Edit parting surfaces.
 Identify user defined parting sheets.
 Extract core and cavity regions.
 Create linked core and cavity models.
 Use Enlarge Surface to create a simple Parting.
 Create Sub-Inserts
This lesson contains the following activities:

Activity Page
5-1 Parting Curves on a Planar Parting . . . . . . . . . . . . 5-11
5-2 Natural Parting with Isocline Curves . . . . . . . . . . . 5-16
5-3 Selecting Transition Objects . . . . . . . . . . . . . . . . . . 5-25
5-4 Parting Surface Creation . . . . . . . . . . . . . . . . . . . . . 5-42
5-5 Core and Cavity Regions . . . . . . . . . . . . . . . . . . . . . 5-70
5-6
5-7
Diagnostics in the Extract Regions Dialog . . . . . .
User Defined Parting . . . . . . . . . . . . . . . . . . . . . . . .
5-74
5-81
ÏÏÏ
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5
5-8
5-9
Topology Change to Product Model . . . . . . . . . . .
Compare and Swap . . . . . . . . . . . . . . . . . . . . . . . . .
5-86
5-101
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EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-1
Core and Cavity Definition

Parting

MoldWizard offers a suite of functions that simplify construction of parting


surfaces and provide the potential to maintain associativity when product
models are modified or replaced.

The Parting Functions dialog appears when you select the Parting icon:

Auto Process
When activated, automatically chooses the four main buttons Parting Lines,
Parting Surfaces, Extract Regions, and Cavity & Core, in sequence. As you
complete tasks inside each submenu, MoldWizard displays the next submenu
from the dialog above.

ÏÏÏ
The setting of Auto Process when the dialog appears (checked or unchecked) is
controlled in mold_defaults by MW_PartingAutoProcess. A value of 1 will
ÏÏÏ
5 enable the option by default, and a value of 0 will make the option disabled by
ÏÏÏ
ÏÏÏ
default. We chose to uncheck the option by default for this class.

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Core and Cavity Definition

Parting Lines
When you select the Parting Lines button in the Parting Functions dialog, the
following menu appears.

The Parting Lines dialog contains tools with which you identify Parting Curves
and Edges.

Using Auto Search Parting Lines, MoldWizard identifies existing edges that are
appropriate for modeling parting surface.

Split Faces allows you to detect and remedy some situations where the natural
parting for the part occurs across a face as opposed to along an edge.

The Transition Objects area provides tools to define and edit transition
geometry or corner points". The system will typically fill in" areas adjacent to
ÏÏÏ
ÏÏÏ
5
transition objects with swept or planar faces. ÏÏÏ
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EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-3
Core and Cavity Definition

Auto Search Parting Lines

When you choose Apply in the Search Parting Lines dialog, the system will:

 detect, in most cases, the single best parting loop


 the Product Design Advisor becomes available
 if holes are detected, Auto Patch becomes available.

Select Body

If the part contains multiple solids use the Select Body button to choose a body
to be analyzed for parting curves.

Eject Direction

The ejection direction is usually by choosing a mold coordinate system. By


default, MoldWizard will assume the Z axis of the WCS is the eject direction.
You may specify an ejection direction within the Search Parting Lines dialog.

Product Design Advisor and Auto Patch

ÏÏÏ
ÏÏÏ
The functionality here is identical to the Product Design Advisor and Auto
Patch offered within the MoldWizard Tools dialog and was covered in lesson 3.
5
ÏÏÏ
ÏÏÏ
They are also presented here as a convenience to the user.

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Core and Cavity Definition

Traverse Loop

From the Parting Lines menu, you can use Traverse Loop to select parting
curves and edges manually.

NOTE This option is helpful when you have a model where the
edges are disjointed and non-contiguous in places. This
is most often the case when you are developing a mold for
a part modeled in another CAD system and translated to
Unigraphics.

From the Parting Lines menu, use Traverse Loop to select parting curves and
edges manually.

With Smart Traverse enabled, a continuous parting line segment is


automatically detected when you select one curve or edge. It continues around
the part until parting is unclear due to gaps or the lack of an edge at the next
anticipated parting position. If you select an edge that should not be include in
parting, the status line will display Not a potential parting line, try another one
...".

The initial setting of Smart Traverse is controlled in mold_defaults by


MW_PartingSmartTraverse. A value of 1 will enable the option by default, and
a value of 0 will make the option disabled by default.

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5
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EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-5
Core and Cavity Definition

Edit Parting Lines

Curves and edges may be added to or removed from the parting line definition
manually.

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5
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Core and Cavity Definition

Split Faces

When a face from your model can be seen from both the core and cavity sides
of the mold it is referred to as a Crossover Face. Since MoldWizard uses edges
to create parting curves and subsequently the parting surfaces it is necessary
that the crossover faces be split or subdivided.

Inspect Crossover Faces

Choosing Inspect Crossover Faces will highlight all faces in the model that cross
over parting.

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5
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EDS MoldWizard Design Process
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Core and Cavity Definition

Split Faces by Imprinting

If Selected Faces is toggled, the faces the user


selects from the graphics screen will be the
only faces split.

If Connected Faces is toggled, all faces that


intersect the defined plane will be split.

Existing Datum Plane allows you to select a


datum that is positioned where you want the
split.

Point + Point will allow you to select 2 points


that will define a line which will be used to
split the faces.

Point + X-Y Plane will split the faces paraĆ


lell to the XY plane at the point selected.

Subdivide Isocline Faces

When Subdivide Isocline Faces is selected the system will display all potential
isocline curves to use for subdividing the faces. You have the opportunity to
deselect curves that do not relate to the parting. When you accept the
remaining highlighted curves, the system will subdivide all adjacent faces at the
isoclines. After subdividing, one part of the face will be on the core" side and
the other part on the cavity" side.

Transition Objects
Transition Objects are points or curves along the parting loop which define the
extents of parting edges which can be extruded in a single direction to form a
parting sheet. Transition curves are sometimes used to define bridging surfaces
between adjacent extruded sheets.
 Curve segments that rise above or drop below an otherwise single

ÏÏÏ
ÏÏÏ 
face" parting are very useful as transition objects.
Transition objects are frequently located at corners" of a parting loop.
5
ÏÏÏ
ÏÏÏ
 Transition objects are not needed for planar partings.

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Core and Cavity Definition

Transition Objects
Transition Objects are points or curves along the parting loop which define the
extents of parting edges which can be extruded in a single direction to form a
parting sheet. Transition curves are sometimes used to define bridging surfaces
between adjacent extruded sheets.
 Curve segments that rise above or drop below an otherwise single
face" parting are very useful as transition objects.
 Transition objects are frequently located at corners" of a parting loop.
 Transition objects are not needed for planar partings.

Auto Transition Objects

Auto Transition Objects assists you by automatically detecting parting curves


that belong together" such as coplanar curves or curves with a common parent
face.

Edit Transition Objects


ÏÏÏ
This function allows you to select and deselect curves in the parting loop. When ÏÏÏ
5
you OK the dialog, selected curves are identified as transition objects. ÏÏÏ
ÏÏÏ
EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-9
Core and Cavity Definition

Add Transition Points

If you have sharp corners you probably need to define Transition Points.

NOTE If all Parting Curves lie in a plane you do not need to specify
transition objects. The system will automatically create one single
bounded plane. You saw an example of this feature in the
introductory activity.

If Parting Lines consists of a single 3D Curve (circle, ellipse), you do not need
to specify parting line segments.

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5
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Core and Cavity Definition

Activity 5-1: Parting Curves on a Planar Parting

In the next group of activities you will experience different parting possibilities
and methods to handle them.

The first part has a simple planar parting.

Step 1 Create a mold project for mdp_outlet.

First Part .../outlet/mdp_outlet


Units default (Inch)
Proj Name default (mdp_outlet)
Mold Csys default
Shrinkage Scale Factor 1.008
Work Piece default
Layout Auto Center

Step 2 Define the parting lines. ÏÏÏ


ÏÏÏ
5
 Choose the Parting icon. ÏÏÏ
ÏÏÏ
EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-11
Core and Cavity Definition

 From the Parting Functions dialog choose Parting Lines →


Auto Search Parting Lines.

 Choose Apply to begin processing.

MoldWizard quickly finds and displays the natural parting edges


of this simple part.

 Choose Auto Patch.

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5
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Core and Cavity Definition

 Deselect an edge loop opening on one of the screw posts, as


shown above . . À
Hint: Change to wireframe display, if necessary.

The missing patch face will later provide an example for


diagnostics in the Extract Regions dialog.

Â
 Choose Auto Patch . . . Á

All openings except the one you deselected are patched.

You may shade the view to verify patch creation. ÏÏÏ


ÏÏÏ
5
 Choose Back . . . Â ÏÏÏ
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EDS MoldWizard Design Process
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Core and Cavity Definition

 Choose OK in the Search Parting Lines dialog . . Ã

Tentative parting lines are displayed in green as the Parting


Lines dialog appears. At this point, in a more complex part, we
could perform editing or define transition objects.

Parting Line definition is not complete.

 Choose OK one last time, from the Parting Lines dialog.

The lines change color to magenta as the Parting Functions


dialog is displayed.

ÏÏÏ
ÏÏÏ
We will work with other parting line examples before returning
to complete the outlet project.
5
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Core and Cavity Definition

Step 3 Display the parting body before saving your work.

 Cancel the Parting Functions dialog.

 Make layer 1 the Work Layer.

 Fit the view if necessary.

 Choose File  Close  Save All and Close.

 Choose OK to acknowledge that you really want to save and


close all parts.

This concludes Activity 5-1.

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5
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EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-15
Core and Cavity Definition

Activity 5-2: Natural Parting with Isocline Curves

The next part has no edges that can be used for a parting. It is our familiar
plastic cup, without the holes we added to demonstrate patching.

You will use Isoclines to divide a blend face at the natural" parting.

Step 1 Create a mold project for mdp_cup1.


First Part .../cup1/mdp_cup1
Units default (Inch)
Proj Name default (mdp_cup1)
Mold Csys Specified Later!
Shrinkage Scale Factor Specified Later!
ÏÏÏ
ÏÏÏ Work Piece default
5
ÏÏÏ
ÏÏÏ
Layout Auto Center

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Core and Cavity Definition

Recall that the positive Z direction indicates the direction the part will
be ejected from the mold.

A part of this type will tend to shrink and grip the core as the mold
opens, requiring ejection to be off the core side.
To efficiently mold this part, the cup needs to be inverted. This will
require a Mold CSYS rotated 180 degrees about the YC Axis.

Step 2 Set the Mold CSYS to reflect ejection off the core side of
the mold.

 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.


ÏÏÏ
ÏÏÏ
5
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EDS MoldWizard Design Process
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Core and Cavity Definition

The Mold CSYS dialog opens:

 Set/Verify that Current WCS is toggled ON . . . À

 Choose OK . . Á

The display reorients to match the new Mold CSYS.

 Fit the view.

The eject direction ZC+ will now


remove the part from the core.
The XC-YC plane lies on the flat
bottom of the cup. This is not the
correct parting plane. In fact, the
parting plane for this part does not
lie at any existing edge geometry.
In this, and similar cases where the
parting is not defined by obvious
geometry, a natural parting must be
defined before establishing the Mold
CSYS.

Step 3 Define parting lines.

 Choose the Parting icon.

ÏÏÏ
ÏÏÏ The Parting Functions dialog opens.
5
ÏÏÏ
ÏÏÏ
 From the Parting Functions dialog, choose Parting Lines.

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5-18 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Core and Cavity Definition

The Parting Lines dialog opens.

 From the Parting Lines dialog, choose Auto Search Parting


Lines.

The Search Parting Lines dialog opens.

 Choose Apply.

The MoldWizard system finds an edge . . . À


In this case, we know the natural parting occurs at the vertical
location of the blend face, as shown below . . . Á
The edge, shown as a dashed line in the illustration, is well
within a fixed distance tolerance for undercuts, but is not precisely
the natural parting.

ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
À
ÎÎÎÎÎÎÎ
Á ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
What if the part ÎÎÎÎÎÎÎ
were not so simple. Could MoldWizard reveal
this information?
The Product Design Advisor has become available. It is a good
habit to check the Advisor even when you do not suspect
problems.

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5
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EDS MoldWizard Design Process
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Core and Cavity Definition

 Choose Product Design Advisor.

 Select Crossover Faces.

The MoldWizard system found one crossover face, and


highlighting reveals it is the blend. This is our cue to subdivide
the crossover face at the zero degree Isocline curve.

 Choose Back to return to the Search Parting Lines dialog.

 Choose Back once again to return to the Parting Lines

ÏÏÏ
ÏÏÏ
dialog.

5
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Core and Cavity Definition

 Choose Subdivide Isocline Faces.

The system finds the isocline of the blend, the only crossover
face in the part. The Deselect Isoclines function is active:

 Choose OK to accept the highlighted isocline curve for


further processing.

 Choose Auto Search Parting Lines.

 Choose Apply.

NOTE The above step is important. You need to dismiss the


edge found earlier and identify a new edge, at the isocline
position, as the parting curve.

 Choose OK in the Search Parting Lines dialog to continue


processing.

 Choose OK to exit the Parting Lines dialog and accept the


displayed circular spline as the parting loop.
ÏÏÏ
ÏÏÏ
5
The selected loop changes color to magenta, or whatever color
is defined as MW_PartingLinesColor. ÏÏÏ
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EDS MoldWizard Design Process
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Core and Cavity Definition

 Cancel the Parting Lines dialog.

 Make layer 1 the Work Layer.

Step 4 Examine the new split line at the lip of the cup.

 Zoom in on the lip.

 If curve detail is lacking. depending on your hardware, you


can Update Display (using MB3), or use View  Operation
 Regenerate Work, to see both the original blend edge and
the new parting edge.

 From the main menu select Information  Object  Type 


Edge.

 Select the magenta parting edge. The Information window


identifies this edge geometry as a tolerant curve.

 Cancel the Information window.

 From the main menu select Information  Object  Type 


Curve.

 Select the magenta parting curve. The Information window


identifies this curve type as a spline.

The curve is a spline. The system extracts the edges of the split
face as splines, to make it easier later to identify their parent
face. The original isocline was an arc, and it is currently hidden.

The original isocline arc is in layer 255, MW_HideObjectLayer.


Of all the available geometry at the natural parting, the arc is
best suited to orient our mold csys.
ÏÏÏ
ÏÏÏ
5
ÏÏÏ
 Cancel the Information window.

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Core and Cavity Definition

Step 5 Display the top part.

 Choose Window → More Parts...

 Select mdp_cup1_top, then OK.

 Set the display to a Front view. Zoom Out if necessary to


view the WCS.

The orientation of the Mold CSYS was defined to allow for


ejection off the core side of the mold.

The natural parting line was defined and examined.

The principal XC-YC parting plane now needs to be moved to


the natural parting plane and the Mold CSYS redefined.

Step 6 Move the WCS to the Natural Parting plane and redefine
the Mold CSYS.

 Zoom in on the part as shown below:

 Make layer 255 Selectable.

 Choose WCS → Origin... and use the Arc/Ellipse/Sphere


Center function to move the WCS to the center of the
Natural Parting Curve.

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5
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EDS MoldWizard Design Process
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Core and Cavity Definition

 Choose the Mold CSYS icon. The Mold CSYS dialog opens.

 Select/Verify that Current WCS is toggled ON and select OK.

The display reorients to match the new Mold CSYS.

 Make Layer 255 Invisible.

 Fit the view.

Step 7 Set the Shrinkage Factor to 1.008.

NOTE It is important that the orientation and placement of the


Mold CSYS be established prior to assigning a Shrinkage
Factor. In cases where the parting line/plane is not
obvious, first define the principal parting plane, adjust the
Mold CSYS, and only then assign Shrinkage.

Step 8 Save your work.

 From the Menu Bar choose File → Close → Save All and
Close.

ÏÏÏ
ÏÏÏ
 Choose OK to acknowledge that you really want to save and
close all parts.
5
ÏÏÏ
ÏÏÏ This concludes Activity 5-2.

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Core and Cavity Definition

Activity 5-3: Selecting Transition Objects

The part is another cup. This one has a step" in the parting. You will practice
selecting transition objects in a non-planar parting loop.

Step 1 Create a mold project for mdp_cup2.


First Part .../cup2/mdp_cup2
Units default (Inch)
Proj Name default (mdp_cup2)
Mold Csys default
Shrinkage Scale Factor 1.008
Work Piece default
Layout Auto Center ÏÏÏ
ÏÏÏ
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Core and Cavity Definition

Step 2 Define parting lines.

 Choose the Parting icon.

 From the Parting Functions dialog choose Parting Lines →


Auto Search Parting Lines.

 Choose Apply.

The system finds four parting curves, including the same circular
edge it first identified in the cup1 part.
Does the circular edge identified lie in the Core or Cavity? This
information will soon be important.
The undercut distance is only .0006 inches, just over .015 mm.
This distance is less than an internal tolerance. We can safely
ignore this very slight undercut.

 Choose OK to accept the four edges displayed above and


return to the Parting Lines dialog.

There are several ways to approach parting construction in this


example. The basic scenario we will use for this part will produce a
parting that is acceptable in many situations. We will later try other
approaches.

We will use the arc to define a principal parting plane. The edges of
the cut out" segment define a transition area" which MoldWizard
will automatically sweep to complete a parting surface. This approach
is used when parting contours should extend all the way to the edge of

ÏÏÏ
the work piece.

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Core and Cavity Definition

Step 3 Define transition curves.

 Choose Auto Transition Objects.

 Choose the Cavity Faces option . . . À

Earlier, you observed that the parting curves were on the


exterior or cavity face of the cup.
The observation was important because it now helps us to
determine the Face Preference.
This is a relatively rare case where the desired result is obtained
only with the correct Face Preference option, Cavity Faces,
because one of the curves lies on cavity faces.

 Choose Show Coface Segments . . Á

NOTE: The Show Coface Segments option must be chosen even


if it is already highlighted as enabled.

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Core and Cavity Definition

Â
Three segments are identified:
À the arc at the lip of the cup
Á two lines that lie on the outer conical face
 an arc that also lies on the outer face.
Segment dividing points are created where adjacent curves
are not tangent.

 Choose Convert Transit Objects.

All three curves in the cut out" section adjacent to the conical
face of the cup are identified as transition curves. The interior"
points of the segment are removed. Transition curves are
displayed in MW_PartingTransitObjectColor, olive by default.
In a later operation, this area of the parting will be
automatically constructed as a sweep surface.

À
Á

 Choose OK to exit the Auto Transition Objects dialog.


ÏÏÏ
ÏÏÏ  Choose OK to exit the Parting Lines dialog.
5
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The system will return to the Parting Functions dialog. All


parting curves, including transition curves, should change color
at this time, indicating that the system has added them to the
UM_PARTING_LINES group.
We remind you again that this color was customized for the
class. The default setting is green, the same as the default curve
color. Changing the color provides a good visual cue to help to
avoid errors.

Step 4 Display the parting body before saving your work.


 Cancel the Parting Functions dialog.

 Make layer 1 the Work Layer.

 Fit the view.

 From the Menu Bar choose File  Close  Save All and
Close.

 Choose OK to acknowledge that you really want to save and


close all parts.

In a later activity you will create a parting sheet that extends to the
outer perimeter of the work piece, as shown below.

ÏÏÏ
ÏÏÏ
5
This concludes Activity 5-3. ÏÏÏ
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EDS MoldWizard Design Process
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Core and Cavity Definition

Parting Surfaces

This function creates parting trim sheets for core and cavity. Sheets may be
interactively constructed by a number of methods. There is also provision within
the final step in the process, Sew Surfaces, to identify manually created sheets.

Tolerance

This value is used as both surface creation and sew tolerance.

Distance

The intent of this value is to make certain the parting faces are big enough to
trim the insert. The default is usually a good value. If you need to enter a value,
choose a distance large enough to exceed the size of the insert, plus a safe
margin for changes.

ÏÏÏ
ÏÏÏ
NOTE You may edit the parting extrusion distance using the expression
editor. Change the variable named parting_extrude_distance in the
5
ÏÏÏ
ÏÏÏ
parting part file.

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Core and Cavity Definition

Create Parting Surfaces

Creating parting surfaces is a two step process.

 In the first step, either use automated tools to create sheets directly
from identified parting curves, or, create your own sheets.
 In the second step, sew the parting sheets together to form a
continuous boundary from the parting body to the extremities of the
work piece.

MoldWizard will analyze previously identified parting curves. Depending on the


result of that analysis, the Create Parting Surfaces dialog might appear, and
may contain one or more applicable options.

For planar parting curves with no transition objects, the system will not display
the parting surfaces dialog. Instead, you will see the dialog shown below, from
which you may elect to create a single parting surface by choosing OK. Choose
Cancel if you want to go back and identify transition curves:

You saw the above dialog during your mdp_tray preview activity.

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5
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All Rights Reserved Student Manual 5-31
Core and Cavity Definition

Extrude

Choose Extrude when a parting line segment, or set of curves between


transition objects, can be extruded in a single Extrude Direction. Extrude uses
the Distance parameter.

Extrude Direction

When you choose the Extrude Direction button you are presented with the
standard Vector Constructor dialog:

Skip
ÏÏÏ
ÏÏÏ If you do not want to a create a surface for a parting line segment, bypass the
5
ÏÏÏ
ÏÏÏ
segment by choosing Skip.

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Bounded Plane

The option to create a local bounded plane" appears if planar segments are
detected. A segment" consists of all the parting curves between, but not
including, a pair of transition objects.

Bounded plane is used when:

 No single extrude vector direction is possible.


 The angle between directions is greater than 180°.

When you select Bounded Plane, the available buttons change as shown below:

When the bounded plane dialog options appear, the system is ready for an
interactive sequence to define the extents of a bounded plane."

 The system temporarily displays a 1" and a 2" at the ends of a


highlighted parting segment.
 Choose First Direction.
Use the Vector Constructor to define a Trim Line" extending from the
ÏÏÏ

parting segment end numbered 1. In the example shown on the
following page, the First Direction will lie along the +Y Axis. ÏÏÏ
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Core and Cavity Definition

1
First Direction defines the orientation of a
“trimming line” extending from this point

2
Highlighted Parting Segment

 Once the First Direction is established, additional controls are added


to the dialog, as shown below:

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 Select Second Direction to open the Vector Constructor dialog and


define the orientation of the trimming line" that extends from point 2.
In this example, the Second Direction will lie along the -Y Axis.

First Direction

2
+ Region Point

Second Direction

 Select OK to accept the Second Direction definition and return to the


Parting Surface dialog.
 Select OK again, this time in the Parting Surface dialog. The View
Trimmed Sheet dialog will open and one of two parting surface
configurations will display.

Select to view alternate sheet

 When the correct sheet configuration is displayed, Choose OK to


create the parting sheet.

The correct sheet configuration for this example is shown below:

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EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-35
Core and Cavity Definition

Swept

Swept is used when:


 No single extrude vector direction is practical.
 The angle between directions is less than 180°.

The swept option, as the name implies, sweeps the profile along two lines which
extend Distance" along directions you specify.
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Bounded Choose Sweep for these segments

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Plane sides. We specify two directions as

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
This Transition Segment will automatically be
swept to fill the area between two swept edges.
D

These Transition Segments, one on each side, will


First be swept to fill the area between a swept edge and

ÏÏÏ
Direction an edge of the bounded plane.

ÏÏÏ
5
Second Second

ÏÏÏ
Direction Direction

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Enlarged Surface

When a segment is detected with a single parent face, you have an option to
create an enlarged surface.

The Enlarged Surface dialog behaves similarly to the Bounded Plane option.
Instead of a being a flat face, the parting face will have the shape of the parent
face of the curves in the highlighted parting line segment. (The option will
appear only when all curves in the segment have the same parent face.)

We noticed earlier that MoldWizard creates extracted edge curves in place of


isocline curves when defining partings. We stated that the system needs to
efficiently determine the parent faces of parting curves.
ÏÏÏ
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5
We now see that providing the ability of the system to determine the parent ÏÏÏ
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EDS MoldWizard Design Process
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Core and Cavity Definition

faces of parting curves enables the display of Bounded Plane and Enlarged
Surface parting functions when they are applicable. The system will recognize
when a segment is planar, or when all curves in the segment belong to a
common face.

Occasionally, all curves in a segment will belong to two common faces, one face
on either side of the curve string. If that situation happens, the dialog will
display an additional option, Flip Face. This enables you to toggle between the
two possible faces that belong to the curve string.

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Choosing a Parting Surface Type

MoldWizard highlights
parting segment

ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
Planar Face?

ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎ No
ÏÏÏÏÏÏÏ Yes

ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
1 Direction Practical?

ÎÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ No
ÏÏÏÏÏÏÏ Yes

ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
Angle between

ÇÇÇÇÇÇÇÇ
directions < 180°? EXTRUDE

ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎ No
ÏÏÏÏÏÏÏ Yes

BOUNDED PLANE SWEPT

ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
Same Surface?

ÎÎÎÎÎÎÎ ÏÏÏÏÏÏ
ÎÎÎÎÎÎÎ ÏÏÏÏÏÏ
No Yes

ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
1 Direction Practical? ENLARGED SURFACE

ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
ÎÎÎÎÎÎ ÏÏÏÏÏÏÏ
No Yes

SWEPT EXTRUDE
ÏÏÏ
ÏÏÏ
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Edit Parting Surfaces

The system will prompt you to pick a parting line or a transition object.

The system will identify the child parting face of the object you select, and
present the appropriate editing dialog for that sheet.

Sew Surfaces

Sew Surfaces automatically selects all system generated parting surfaces. You
will be presented with a Select Sheets prompt, from which you may add or
remove surfaces, including sheets that were not created by the MoldWizard
system. Click to select, or shift-click to deselect. When you choose OK in the
Select Sheets dialog, the system will sew all sheets.

You must use the Sew Sheets function even if you have only user defined
partings. When you select sheets, no matter how they were created,
MoldWizard applies attributes to identify them as parting faces. The original
sewn feature is identified for later use in the core trim sheet. The system
extracts a copy to use in the cavity trim sheet.
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Auto Cavity_Core

The Auto Cavity_Core function automates the process steps of Sew Surfaces,
Extract Regions, Create Cavity and Create Core. This function can be applied
only to a non-planar parting condition that requires sewing.

To apply the Auto Cavity_Core function, follow the normal MoldWizard Design
process up to and including the creation of parting lines and non-planar
parting surfaces. Selecting the Auto Cavity_Core option will then launch an
automated process for creating a finished cavity and core.

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Activity 5-4: Parting Surface Creation

Step 1 Create a mold project for mdp_dryer.


First Part .../dryer/mdp_dryer
Units default (Millimeter)
Proj Name default (mdp_dryer)
Mold Csys specified later!
Shrinkage Scale Factor 1.008
Work Piece Wait for Mold Csys!
Layout Wait for Mold Csys!

ÏÏÏ
ÏÏÏ
 After you set shrinkage, set mdp_dryer_top as Work Part.
Hint: Assemblies  Context Control  Set Work Part 
5
ÏÏÏ
ÏÏÏ
Displayed Part.

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Step 2 Orient the WCS in two stages.

 From the Menu Bar choose WCS → Rotate...

 Choose the radio button -YC Axis: XC->ZC.

 Verify that the Angle value is 90.0000.

 Choose Apply.

 Choose the radio button +ZC Axis: XC -> YC.

 Choose OK.

The WCS should be oriented with YC+ along the handle, XC+
pointing toward the nozzle and ZC+ pointing toward the vent
area.

 Choose the Mold CSYS icon.

The Mold CSYS dialog opens.

 Set or Verify that Current WCS is ON . . . À

 Choose OK . . Á

The display reorients to match the new Mold CSYS. ÏÏÏ


ÏÏÏ
5
 Fit the view. ÏÏÏ
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Core and Cavity Definition

The system aligns the WCS of the product subassembly with the
ACS of the mold assembly.
The dryer should be now be oriented as shown below in the
TFR-TRI view or Trimetric view orientation.

Step 3 Complete the remaining initialization steps.


 Accept the defaults for Work Piece.
 Auto Center the Layout.
 Fit the view.

Step 4 Investigate the parting properties of the product model.


 Choose Parting → Parting Lines → Auto Search Parting
Lines.
 Choose Apply to begin processing.
After a few moments MoldWizard finds 23 parting edges.

ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
Both Product Design Advisor and Auto Patch have become
available.

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Core and Cavity Definition

 Choose Product Design Advisor and check Vertical Faces.


The system detects six Vertical Faces, two for each of the three
button openings.
There are three button openings in the handle, and eleven vent
openings in the fan housing. These openings require patching.
 Compare Cavity Patch Loops and Core Patch Loops.
The system identifies the same fourteen patch loops for both the
Cavity and Core side of the mold. This indicates that enough
draft has been included in the part design to remove any
ambiguity concerning where the patch sheet bodies should be
located.
 Choose Back from the Product Design Advisor dialog. The
Search Parting Lines dialog displays.

Step 5 Auto Patch the holes.

TIP In some cases where Auto Patch would create a large


number of Edge Patches, manual patching using another
method is faster.

 Choose Auto Patch.


The Patch Loops Selection dialog opens.

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Core and Cavity Definition

The Cue reads:


Select a patch method.
Recall that in cases where sufficient draft is designed into the
part, MoldWizard will always defer to what it determines to be
the correct patch location (core side or cavity side).
In this example, MoldWizard will correctly locate the patch
surfaces (on the cavity side) regardless of the Patch Method
specified.
The status window reads:
Found 14 patch loops. Deselect those loops that you don't want to patch.
This activity uses all 14 patch loops.

 Set the Display Mode to Shaded.

 Choose Auto Patch . . . À

MoldWizard patches the button and vent openings in a manner


consistent with the draft that was designed into the part model.

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Patches now cover the


three Button and
eleven vent openings.

 Set the Display Mode back to Wireframe.

 Choose Back to return to the Search Parting Lines dialog.

 Choose OK again, in the Search Parting Lines dialog . . . À

The Parting Lines dialog opens and the tentative parting line
ÏÏÏ
ÏÏÏ
5
displays in green. ÏÏÏ
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Core and Cavity Definition

Step 6 Define transition curves.

 From the Parting Lines dialog choose Auto Transition


Objects.

Eight points of transition display.

 Accept the default settings by choosing Convert Transit


Objects.

The six curves shown in the figure below highlight in olive.


These are the transition curves that do not lie on the XC-YC
plane.

Three lines in this area

Á This arc
À Â

Å
Two tiny draft lines
in these locations

 Choose OK to exit the Auto Transition Objects dialog and


return to the Parting Lines dialog.

 Choose OK one last time, from the Parting Lines dialog.

The Parting Functions dialog reappears and the parting lines


change to magenta.
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How Does it Work?


MoldWizard remembers parting curves you select by creating a
named group, UM_PARTING_LINES.
MoldWizard identifies transition points by placing them into a
named group UM_TRANSIT_POINTS.
MoldWizard identifies transition curves by assigning a name
attribute, UM_TRANSIT_CURVES, to each transition curve.

Step 7 Create the front planar parting surface.

 From the Parting Functions dialog choose Parting Surfaces.

 Choose Create Parting Surfaces . . À

ÏÏÏ
ÏÏÏ
5
The Parting Surfaces dialog appears. Bounded Plane is
automatically selected. ÏÏÏ
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Core and Cavity Definition

One of two possible parting segments highlights:

Á Front Segment
 Rear Segment
We will create the Front Segment/Surface first.

 If the Front Segment is not highlighted, simply select it on


the graphics screen . . . Á

MoldWizard allows you to create parting sheets in any order, by


highlighting the segment with which you wish to work.

 Choose First Direction . . . Ã

ÏÏÏ
ÏÏÏ
The Vector Constructor dialog opens.
5
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First Direction defines the direction of the parting surface edge


that that will extend from the endpoint of the segment labeled 1.

NOTE The numbers 1 and 2 may be reversed in your part file.

 In Vector Constructor dialog, choose an appropriate direction


for the point labelled 1.

 Choose OK.

 Fit the view.

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Vector Arrows and dashed lines appear in the specified


direction.

V
2
1

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The Parting Surface dialog updates to reflect new choices:

 Choose Second Direction . . . . Ä

The Vector Constructor dialog reappears.

 From the Vector Constructor dialog, choose an appropriate


direction for the point labelled 2.

A Vector Arrow appears in the matching direction.

 Choose OK in the Vector Constructor.

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Core and Cavity Definition

The Parting Surface dialog reappears. The display updates.

V
2
1

 Select OK again, in the Parting Surface dialog . . . Å

Å
ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
The View Trimmed Sheet dialog opens and one of two possible
parting surface configurations displays.

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Core and Cavity Definition

 Choose Flip Trimmed Sheet as necessary to view the two trim


sheet alternatives . . Æ

È
 When the correct sheet configuration is displayed . . Ç
choose OK in the View Trimmed Sheet dialog . . . . . È

Step 8 Create the rear planar parting surface.


 In the Parting Surfaces dialog choose First Direction.
The Vector Constructor dialog opens. ÏÏÏ
ÏÏÏ
5
First Direction defines the direction of the parting surface edge
that extends from the endpoint labeled 1. ÏÏÏ
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EDS MoldWizard Design Process
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Core and Cavity Definition

NOTE The numbers may be reversed in your part file.

 In Vector Constructor dialog, choose an appropriate direction


for the point labelled 1.

 Choose OK.

 Fit the view.

The Parting Surface dialog updates.

Vector Arrows appear in the matching direction.

 Choose Second Direction.

 From the Vector Constructor dialog, choose an appropriate


direction for the point labelled 2.

A Vector Arrow appears in the matching direction.

 Choose OK.
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The Parting Surface dialog once again displays.

Vector Arrows have appeared in the matching direction.

2 V

 Choose OK in the Parting Surface dialog.

The View Trimmed Sheet dialog opens and one of two possible
parting surface configurations display.

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Core and Cavity Definition

 If necessary, use Flip Trimmed Sheet . . À


to obtain the correct configuration . . . . Á
and then choose OK . . . Â

À
Â

When the second planar sheet configuration is accepted, the


system creates the second sheet and two transition sheets:

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Step 9 Examine the sheet body that extends from the electrical
cord opening.
The sheet body that extends from the electrical cord opening
appears to have three faces.

 Choose Information  Object  Type  Face.

 Select one of the faces of the sheet body that extends from
the electrical cord opening.

This sheet body has a single face.

 Shade the part and Zoom In to observe how the sharp edges
were rounded.

A very brief explanation of how tolerance is used in free form


sweep situations follows.

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Core and Cavity Definition

When MoldWizard creates a sweep of two or more transition


curves, it uses the modeling tolerance specified in the Create
Parting Surfaces dialog.

The sweep function creates a


spline to approximate the given
section curves. This spline is
internally smooth. Near sharp
corners, it is constrained to lie
inside the tolerance zone.

Tolerance Zone uses the Tolerance value


on each side of input curves

At sharp corners, the section curve is approximated according to


the rule shown above.
The single face sheet could be inconvenient for an NC
operation.
Free Form Swept surfaces may have a zero tolerance. With a
zero tolerance Unigraphics does not approximate the section
string as one curve. A separate face is created for each curve.

NOTE This edit is desirable if adjacent edges are not tangent.

For more information please refer to the On Line Help for Free
Form Swept surfaces.

 Return the Display Mode to Wireframe.

ÏÏÏ
ÏÏÏ  Fit the view.
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Step 10 Edit the sweep parameters.

 Cancel from the Create Parting Surfaces dialog.

 Choose View  Model Navigator, or, choose the icon:

 Choose Application  Modeling.

 Use highlighting to locate the PARTING_SWEPT feature


that corresponds to the electrical cord opening.

TIP Use MB1 to select a line in the Model Navigator. The


corresponding feature will highlight on the graphics
screen.

NOTE Your feature numbers may differ from those depicted.

 Double-click the appropriate PARTING_SWEPT icon . . . À

NOTE Do not click the check box - that suppresses the feature.

TIP When you double click in the Model Navigator, it is best


to click over the icon, as shown above. If you click over
the name, and do not click fast enough, the system
assumes you want to rename the feature!
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The Edit Parameters dialog appears:

 Choose the Tolerance button . . . Á

 Type 0 (figure zero) as the new Tolerance . . Â

 Choose OK . . Ã

Â
Ã

 Choose OK again in the Edit Parameters dialog.

The part updates with three faces, one for each curve at the

ÏÏÏ
ÏÏÏ
electrical cord opening.

5
ÏÏÏ
ÏÏÏ
This can be verified by repeating the Information actions.

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NOTE The Tolerance in the Create Parting Surfaces dialog is


also used for trim and sew tolerance. It is not appropriate
to enter a zero value there. In fact, it is not allowed.

 Dismiss the Model Navigator window.

Step 11 Sew the parting sheets.


 Choose Parting  Parting Surfaces.

 Choose Sew Surfaces . . À

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NOTE Sew Surfaces is an essential step in all cases where there


are more than one parting sheet.

The system gives you the opportunity to:


 add user defined sheets
 remove redundant sheets

 Choose OK in the Select Sheets dialog.

Step 12 Display the shrink body before saving your work.

 Make layer 1 the Work Layer.

 If you wish, adjust the view orientation and zoom factor


before saving.

 Select File  Close  Save All & Close.

This concludes Activity 5-4.


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Extract Regions

Previously defined parting lines and surfaces will be used as boundaries as the
system extracts regions", or bounded groups of faces, from the parting part.

These regions are assigned to either the cavity or core side of the mold insert,
and subsequently used to trim the cavity and core seed blocks into the shape of
the product and parting.

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In the Extract Regions dialog, the total number of faces on the parting part and
the numbers of cavity and core faces are displayed. The total should equal to
the sum of cavity and core faces.

Two slide bars make previewing and checking cavity and core faces easy.

If Total Faces is less than the number of core and cavity faces combined you
probably have an un-patched hole. Using the slides to slowly highlight one
region, you can easily spot where the hole is. Face highlighting will suddenly
enter the other" region (Core or Cavity) as you highlight faces in or adjacent
to the hole.

ÏÏÏ
ÏÏÏ
If the total faces is greater than the sum of core and cavity region faces, you may
have created an internal empty volume (with solid patch) or you might have
5
ÏÏÏ
ÏÏÏ
created duplicate patch surfaces. Correct the error before proceeding.

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Core and Cavity Definition

TIP If you have manually prepared faces for core and cavity regions, any face
that crosses the parting must be split or subdivided.

Rarely, the system might not interpret the parting boundary as you want it. You
can modify the system selected cavity and core boundary edges or faces. Four
radio buttons, Cavity Only, Core Only, Both, and Boundary Edges, control
boundary editing selections. Various buttons on the dialog are available
depending which option is active. In edit mode, you may Select or
Shift-Deselect boundary faces or edges.

TIP Try to use a simple region boundary to edit. Depending on the


product shape, sometimes one region boundary is easier to edit
than the other. Try to avoid using the Both option because you will
need to edit two region boundaries instead of one.

The default Edit Boundary setting is Boundary Edges. This can be modified in
the mold_defaults file by editing the value of MW_PartingRegionType.

MoldWizard automatically identifies core and cavity regions based on surface


normals and the ZC+ direction. In very rare cases it is not clear which subset of
the part faces belong to core or cavity. If this occurs you will be prompted to
select a seed face for the region(s) that could not be determined.

When you choose OK in the Extract Regions dialog, MoldWizard automatically


creates Extract Region features and identifies them for use in core and cavity
tool definition.

The layers for these region features are determined by mold_defaults settings:
MW_PartingCoreSurfLayerName: CoreSurface
MW_PartingCavitySurfLayerName: CavitySurface
MW_PartingCoreSurfLayer: 27 ÏÏÏ
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MW_PartingCavitySurfLayer: 28
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Core and Cavity

Check Geometry

If this option is enabled, after you select sheets for the core or cavity,
MoldWizard will run a geometry check and report invalid sheets before sewing.

Check Overlapping

If this option is enabled, after you select sheets for the core or cavity,
MoldWizard will check for overlapping geometry before sewing.

Create Cavity, Create Core

The Create buttons automatically run checks if checking is enabled, sew the
corresponding defined region to an extracted copy of the parting surfaces,
activate trim when enabled, then temporarily display the tooling body.

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WAVE relationships in the seed parts link the shrink body to the
original part, and the parting body to the shrink body. When you
create the Core and Cavity, the WAVE relationship is extended to the
tooling, via linked tooling bodies and linked trim seed sheets.

The core seed sheet is used as a target solid. The seed and the
original parting surface are mutually trimmed and sewn together with
the extracted core region. Thus the copy of the core seed in the
tooling part is updated to reflect the parting and core region. A linked
copy of the workpiece and the trim feature are in place in the seed
assembly, but the trim feature is suppressed by expression. When you
Create Core, all that MoldWizard needs to do is edit the trim
expression and temporarily display the part.

The cavity follows exactly the same process, except it uses a linked copy of the
original parting sheet.

MoldWizard provides the following dialog to return you to the parting part
when you have finished examining the work piece.

IMPORTANT Note!
When you reopen tooling projects from disk, default settings on your
system may enable partial loading, to conserve memory usage.

The Core_Cavity process will not be able to finish unless WAVE


linked geometry is loaded.

Activating MoldWizard before you open your tooling assembly is all


that you need to do.

Choosing Application → MoldWizard sets File → Options → Load


Options to enable Load WAVE Data.

If you have WAVE, you can manually open WAVE linked parts in a ÏÏÏ
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previously opened assembly using the Assemblies WAVE options.

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Core and Cavity Definition

Activity 5-5: Core and Cavity Regions

In this activity you will continue work on your mdp_cup1 project.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open your cup1 project.

 Open cup1/mdp_cup1_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / cup1_2 /

Step 2 Process the parting geometry and create core and cavity.

 From the MoldWizard tool bar choose the Parting icon.

 In the Parting Functions dialog enable the Auto Process


option, as shown in the figure below.

Earlier we defined a parting curve in this project. Now that you


know all the necessary steps to process geometry, you can
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appreciate what Auto Process does.
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Auto Process is the default setting. We turned it off for this class,
to help you to become familiar with using Parting Functions.

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 Choose Parting Surfaces.

 Choose Create Parting Surfaces.

 Choose OK.

The Extract Regions dialog now appears, because you selected


Auto Process.

 Fit the view to see the parting surface.

The sum of core faces, 5, and cavity faces, 4, equals the total
faces, 9.

 Choose OK.

The Core & Cavity dialog appears.


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If the system can not determine cavity and core, a dialog


will appear asking you to pick a seed face.

MoldWizard determines core and cavity by examining the


difference in surface normal vectors of faces adjacent to
the parting. The above dialog appears extremely rarely.

 Choose Create Cavity.

 Choose OK in the Select Sheets dialog.

In a few moments the Cavity tooling part, mdp_cup1_cavity,


appears.

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Let's take a moment to see what Reverse Normal does.

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 Choose Reverse Normal.

Reverse Normal changes the trim direction of the parting sheet.


If for any reason the system selects the wrong trim direction,
you would correct it using the Reverse Normal button.

 Again, choose Reverse Normal in the View Parting Result


dialog.

NOTE The above step is essential to achieve the original and


correct parting trim direction.

 Choose OK in the View Parting Result dialog.

 Choose Create Core.

 Choose OK in the Select Sheets dialog.

 Choose OK.

Step 3 Save your work.

 Change the Displayed Part to mdp_cup1_top.

 Fit the view.

 Choose File  Close  Save All and Close.


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Core and Cavity Definition

Activity 5-6: Diagnostics in the Extract Regions Dialog

You will discover how an unpatched hole is diagnosed by the Core & Cavity
dialog, and explore tools to find problem geometry and make corrections.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open your outlet box project.

 Open outlet/mdp_outlet_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / outlet_2 /

Step 2 Create Parting Surface.

 From the MoldWizard tool bar choose the Parting icon.

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 Choose Parting Surfaces.
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 Choose Create Parting Surfaces.

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A Warnings dialog appears:

 Choose OK in the Warnings dialog.

 Fit the view to see the parting surface.

Earlier, you patched the holes in the outlet face using Auto
Patch. You deliberately removed one screw post hole from the
system selection. You will now observe the effect of that missing
patch.

Step 3 Define Core and Cavity regions.

 From the Parting Functions dialog choose Extract Regions.

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Notice that the Cavity Faces plus the Core Faces add up to more
than the Total Faces.

The Status line reports that 82 overlapping faces were found,


zero faces were not used, and there are no void faces.
 Set the Display Mode to Shaded.
During the next action step, observe the part from above. These
outer faces of the part are the Cavity Regions that will form the
mold cavity.
 Move the Cavity Face slider carefully from left to right and
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observe the cavity face regions as they highlight.
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When the interior face of one of the corner mounting holes
highlights, rotate the part to view the underside.

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 Continue to move the Cavity Face slider to the right and


observe how the detected cavity regions tend to spill over into
the under (core) side of the part.
The highlighting faces on the under (core) side of the part are
the overlapping faces MoldWizard detected.
This overlap occurred because the hole that was deselected (not
patched) during the Auto Patch procedure, allowed region
detection to spill across the desired parting to the other side.
Resetting the Cavity Face slider back to zero and moving the
Core Face slider will demonstrate the same spill over effect from
the core side.
 Set the Display Mode back to Wireframe, Fit the view and
select Cancel.

Step 4 Patch the remaining hole.


 Choose the Tools icon.
 Apply a Surface Patch on the lower face of the mounting
screw post with no patch.
 Cancel the Tools dialog.

Step 5 Define Cavity and Core regions.


 Choose the Parting icon.
 Choose Extract Regions.

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This time the Status line reports Searching core/cavity
boundaries..." and the face counts add up perfectly.
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 Use the sliders to examine the core and cavity regions.

 Choose OK to accept the region definitions.

How Does it Work?


A region feature is a set of contiguous faces defined by a start
face and a boundary. The region contains any face that can be
reached" from the start face without crossing the boundary.
Boundary faces are included in the region.
A region definition is associative. If faces inside the boundary
change, for example by the addition of a pad or boss, the Extract
Region feature will update to include the new faces.
MoldWizard constructs a region boundary based on faces
adjacent to defined parting curves.

TIP Be careful about the addition of holes. An unpatched


hole will permit faces to be reached" that should have
been outside the region, as you saw in the example part.

The Cavity and Core regions that you defined will be used
together with parting faces and Wave links to create trimmed
blocks for cavity and core tooling.
Core and cavity region features in the parting part are a primary
associative link between tooling and product model.

Step 6 Create Cavity and Core Tooling Pieces.

 If necessary, choose Parting.

 Choose Cavity_Core.

 Choose Create Cavity.

The system should highlight the cavity region and one copy of
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the large planar parting face, and display a Select Sheets dialog.
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This would be your opportunity to select other user defined
geometry for use in trimming the cavity work piece.

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 Choose OK.

The system displays the parting result for your examination.

 After examining the part, select OK to return your display to


the parting part.

 Choose Create Core.

 When you have examined the part and it appears as shown


below, choose OK to return your display to the parting part.

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Step 7 Save your work.

 Display mdp_outlet_top.

 Choose File  Close  Save All and Close.

This concludes activity 5-6.

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Activity 5-7: User Defined Parting

A user defined parting can be any face created via Enlarge Surface with the As
Existing Surface" trimming option, or any face manually selected when you
define parting sheets.

You will now define Core and Cavity tooling using this sheet. It is important to
add this approach to your repertoire of techniques for parts where a single face
defines a contoured parting.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open your case6 project.

 Open case6/mdp_case6_top.

If needed, a staged assembly for this activity is in:


.../ moldwizd / case6_2 /

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Step 2 Create cavity and core regions.


 Choose Parting  Extract Regions.
The technique you will use is most powerful with parts where a
single face can be enlarged to form a useful parting sheet.
It is interesting to note that this part currently has no defined
parting lines, nor any defined parting sheets.
Use the sliders to verify that the system has correctly identified
the exterior of the case as cavity and the interior as core.
 Choose OK to create the region features.

Step 3 Create the Cavity and Core.


 Choose Cavity_Core from the Parting functions dialog.

 Choose Create Cavity.


Notice that MoldWizard appears to have identified the sheet
you created with enlarge surface. In fact, when you enabled As
Existing Surface, the system made copies of the sheet, one each
for cavity and core. It is the extracted copy in layer 28 that you
see now. (The layer is controlled in the default file.)
 Choose OK in the Select Sheets dialog.
Examine cavity tooling work piece.

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 Choose OK to return to the parting part.

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 Choose Create Core.

Notice in the Work Layer toolbar that you are now examining
objects in layer 27.

 Choose OK in the Select Sheets dialog.

Examine core tooling work piece.

 Choose OK to return to the Parting Functions dialog.

Step 4 Save your work and close the currently open assembly.

 From the Menu Bar choose File  Close  Save All and
Close.

This concludes Activity 5-7.

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Core and Cavity Definition

Edit Parting Functions


MoldWizard is able to handle most changes to the product model even after
the Core and Cavity have been defined. The approach to updating your mold
will depend on the nature and complexity of the change:

 Internal Change: Any change of these types will propagate to mold


design automatically:
 the addition of boss, rib, or pocket
 the relocation of such features
 Topology/Parting Change: This includes:
 adding or removing holes / windows
 adding or removing feature(s) that affect parting
 New model This is often the case when the customer is using another
CAD system to design their parts.

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Suppress Parting and Update Parting

The Suppress Parting and Update Parting features are used to edit a mold
design after the cavity & core have been extracted and trimmed. The goal is to
maintain associativity to minimize any rework that may be required.

Procedure for Part Model Topology Changes or New Model

 Suppress Parting
 Assure that the parting file is the work part
 Choose Suppress Parting to suppress the cavity & core region
features and trim features
 If necessary, use Swap Model
 Recreate parting lines and transition objects
 Edit the Parting Surfaces
 Patch new holes
 Delete any unneeded patch and parting sheets
 Edit transition points along the parting loop
 Create new parting surfaces as needed
 Update Parting
 Choose Update Parting to unsuppress features and update
regions and bodies.

TIP In the current release, the Swap Model function removes


parameters from all parting lines and parting surfaces.
For this reason it is important to determine if it will be
more efficient to modify the original product model or
swap model, for each part design change.

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Activity 5-8: Topology Change to Product Model

In this activity we will simulate a customer request to change the part so that
the outlet box can be used with conduit and to add openings for ground fault
condition interrupter (GFCI) buttons.

Step 1 Open your outlet box project.

 Open the product model mdp_outlet.

 Open outlet/mdp_outlet_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / outlet_3 /

Step 2 Suppress parting on your mold.

 Choose the Parting icon.

 Choose Suppress Parting.

Step 3 Create a datum plane to use for a pocket.

 Change your displayed part to mdp_outlet.

 Make the datum planes visible by making layer 61 the Work


Layer.

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À
Á
 Create a datum plane through the near edge (in TFR-TRI
view) and parallel to the center plane as shown above.
Hint: Insert  Form Feature  Datum Plane. Select the
center plane and then the edge. Use zero degree angle.

Step 4 Add a pocket for conduit connection.


 Choose Insert  Form Feature  Pocket.

 Choose Rectangular.

 Select the newly created datum plane


as the placement face . . . À

 Choose Flip Default Side.

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 Select the front edge as the horizontal reference . . Á ÏÏÏ
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 Enter the values shown above.

 Choose OK.

 Use the Line onto Line positioning tool to position the


pocket such that the vertical center line is aligned with the
center datum and the horizontal center line is aligned to the
bottom edge.

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 If the Edit During Update dialog appears, dismiss it using


the Accept Remaining icon.

NOTE Notice that the error occurred in the parting part. This
demonstrates why we recommend suppressing the
parting! With the parting suppressed, the failure of the
planar parting to update will not cause further problems.

Step 5 Relocate the screw hole.


 Choose Edit  Feature  Positioning, select the center
hole from the graphics screen, and choose OK.

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 Choose Edit Dimension Value and select the dimension


shown (dimension should be p68) . . À

À Á

 Enter 1.625.

 Choose OK four times, until the part updates.

The hole should move to the location indicated . . . Á

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Step 6 Duplicate the screw hole using Mirror Feature.

 Choose Insert  Feature Operation  Instance. Choose


Mirror Feature.

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 Select the relocated hole from the graphics screen. ÏÏÏ
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 Choose the Datum Plane selection step icon on the dialog.

 Select the center datum plane from the graphics screen.

 Choose OK.

 Choose Cancel to dismiss the Instance dialog.

Step 7 Add pockets for the GFCI buttons.

 Choose Insert  Form Feature  Pocket.

 Choose Rectangular.

 Select the top face of the outlet for the Placement Face and
the shorter center datum for the Horizontal Reference.

 Enter the Values shown.

 Choose OK.

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 Choose a horizontal dimension.

 Select the datum shown À as a horizontal reference.

 Position the long center line on the datum . . . À


Hint: Use Line onto Line.

 Position the short center line 0.350 from the datum . . . Á


Hint: Use perpendicular.

 Use Mirror Feature to duplicate the pocket using the same


technique as shown above.

 Make layer 1 the Work Layer and layer 61 Invisible.


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Step 8 Create new Patch Surfaces for the newly created holes.
 Change your displayed part back to the parting file by
choosing the Parting icon.

 Choose the Tools icon.

 Make the product model visible by making layer 1 Selectable.


Make the patch sheets visible by making layer 27 Selectable.
Turn shading on. Inspect the holes in the part. Notice the
original screw hole patch surface relocated to the new
position.

 Choose Auto Hole Patch and deselect the five loops for holes
already patched by holding your shift key down while
selecting the patched holes. Three loops will remain
selected.

 Choose Auto Patch to create the surfaces. Choose Back to


dismiss the dialog.

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Step 9 Correct the parting lines by adding the new edges created
by the conduit pocket.
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 Choose the Parting icon then choose Parting Lines.

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 Choose Edit Parting Lines.

open end
À À open end

 Add the six bold edges shown above to the parting.

 Choose Add Transition Points then select the two end points
shown above . . À

 Choose Back to return to the Parting Lines dialog, and then


choose OK.

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Step 10 Replace the parting surfaces.

 Choose Parting Surfaces from the Parting dialog.

 Choose Delete Parting Surfaces Õ Delete All.

 Choose OK.

 Choose Create Parting Surfaces.

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 Use the bounded plane option to create the first surface as


shown below.

NOTE Use U and V factors large enough to be certain that your


plane will trim the work piece.

2
1

 Use the extrude option to create the second surface.

 Choose Back.

Notice that you did not sew the surfaces. Observe the status line
as you perform the next action. The system has the intelligence
to realize that a sew operation is needed. Information will
display very briefly as a sew is performed.

 Choose Update Parting.

The status line should indicate that the update is occurring. The
screen might flicker during update; this is normal. The core and
cavity parts will very briefly display.

 Change your displayed part to the core or the cavity and


confirm that the mold updated as desired.
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 Choose File  Close  Save All and Close.

This activity demonstrated the capability of updating your mold to inherit the
new features introduced to the product model. Since associativity to the sewn
parting surface was maintained all downstream features should update
accordingly

This concludes Activity 5-8.

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Compare and Swap Model

As stated earlier, a mold designer will frequently be given a completely new


model that represents a customers changes to a part for which a mold is already
being developed.

MoldWizard provides tools to compare the before and after condition of the
product model and then exchange the new part for the old one.

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Activity 5-9: Compare and Swap

Step 1 Create a mold project for mdp_handle.

First Part .../handle/mdp_handle


Units default (Inch)
Proj Name default (mdp_handle)
Mold Csys default
Shrinkage Scale Factor 1.006
Work Piece default
Layout Auto Center

Step 2 Define the parting lines.

 Choose the Parting icon.

 Enable the Auto Process option.

 From the Parting Functions dialog choose Parting Lines →


Auto Search Parting Lines.

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 Choose Apply to begin processing.

 From the Search Parting Lines dialog choose Auto Patch 


Auto Patch to patch up the hole on top of the product model.

 Choose Back then OK to accept the parting lines.

 From the Parting Lines dialog choose Auto Transition


Objects.

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 Choose Convert Transit Objects from the Auto Transition


Objects dialog.

 Choose OK in Auto Transition Objects.

 Choose OK in the Parting Lines dialog.

Step 3 Create the Parting Surfaces.

 From the Create Parting Surfaces dialog, choose Create


Parting Surfaces.
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 Use Bounded Plane to create the first (largest) parting


surface as shown below. The trim vectors should be parallel
to the Y axis.

 Use Bounded Plane on the next string as well. Use vectors


parallel to the existing sheets edges.
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Hint: You may need to choose Flip Trimmed Sheet.
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 Choose OK.

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MoldWizard should create your auto-swept surfaces to


complete the parting surfaces as shown.

Step 4 Create the Cavity and Core.

 From the Create Parting Surfaces dialog choose Auto


Cavity_Core.

Auto Core_Cavity automatically sews your parting surfaces, ÏÏÏ


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Step 5 Save your project.

 Change your displayed part to mdp_handle_top.

 From Main menu bar choose File  Save All.

Now we will simulate receiving a newer version of the customers part.

We will first compare the before and after conditions so we can


understand the changes and determine the impact (if any) to our mold
design.

Step 6 Compare the new handle with the existing handle.

 From the MoldWizard tool bar choose Parting.

 Choose Compare Product Models.

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 From the Open File dialog choose mdp_new_handle


MoldWizard opens a three-view layout and overlays the new
and original handles.
 Enable shading for both the new and original models by
swtting Shading to ON . . . À

 Choose Apply . . . Á

À
À

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5
ÏÏÏ
ÏÏÏ
EDS MoldWizard Design Process
All Rights Reserved Student Manual 5-107
Core and Cavity Definition

 Use the translucency slide bars to view the models and fully
understand the changes that occurred.

We can see from the display that the following changes


occurred:
 handle has contours added to the grip area.
 the trigger cut-out has a new shape.
 the opening on the side has changed shape.
 a new blend has been added to the top edge.

Step 7 Swap the handle for the new handle.

 Choose Back the exit the Model Comparison dialog.

 From the Parting Functions dialog choose Swap Product


Model.

 Choose the mdp_new_handle from the Open Part File


dialog.

MoldWizard retrieves the new model and adds it to the product


subassembly", creates links to the shrink part and the parting
part, and suppresses the core and cavity trim.

Step 8 Remove the original parting and patching surfaces


impacted by the change.
ÏÏÏ
ÏÏÏ Make sure that layers 26, 27 and 28 are selectable and all
5
ÏÏÏ

other layers are invisible.
ÏÏÏ
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Core and Cavity Definition

Depending on the severity of the changes, you could choose to


delete all parting and patching surfaces and create new surfaces
in their place. However, this is not necessary. You can choose to
replace only those surfaces impacted by the changed model.

 Choose MoldWizard Tools.

 Choose Parting/Patch Delete.

 Choose Delete Patch Surface . . . À

 Select the patch sheet . . Á ÏÏÏ


ÏÏÏ
5
 Choose OK confirming the delete. ÏÏÏ
ÏÏÏ
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Core and Cavity Definition

 Choose Delete Parting Surface . . Â

 Choose Delete Selection . . . Ã

Ä
Ä

ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
 Select the two sheets illustrated above . . Ä

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Core and Cavity Definition

 Choose OK confirming the Delete.

 Choose Back, and Cancel the Tools dialog.

Step 9 Re-establish Parting Lines and Patch Surfaces.

 Choose the Parting icon from the MoldWizard toolbar.

 Choose Parting Lines  Auto Search Parting Lines 


Apply.

 Choose Auto Patch  Auto Patch.

 Choose Back  OK  Auto Transition Objects  Convert


Transit Objects, and then OK twice.

Step 10 Create the missing Parting Surfaces

 From the Parting Functions dialog choose Parting Surfaces


 Edit Parting Surfaces.

 From the graphics screen select a curve from the outside


string.

Select Here

 Use Bounded Plane option to create the surface. ÏÏÏ


ÏÏÏ
5
 Select a curve from the trigger cut out area. ÏÏÏ
ÏÏÏ
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Core and Cavity Definition

 Choose Auto Surface and Edit Primary Edges.

 Select the two edges illustrated below . . . ÀÁ

Á
À

ÏÏÏ
ÏÏÏ
 Choose OK.
5
ÏÏÏ
ÏÏÏ
 Cancel the Curve/Point Selection dialog.

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Core and Cavity Definition

Step 11 Complete the swap by updating the parting.

 Choose the Parting icon.

 Choose Update Parting from the Parting Functions dialog.

The system takes several moments to recreate various features.


You may now change your displayed part to inspect the new
core and cavity.

Step 12 Save All and Close.

This concludes Activity 5-9.

ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
EDS MoldWizard Design Process
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Core and Cavity Definition

SUMMARY MoldWizard provides useful tools for creating


parting geometry. You learned how to define
parting curves and edges from existing
geometry, and how to use the system to
subdivide faces at isocline curves to create a
natural" parting.

You learned a method to incorporate your own


sheets into the associative parting used by
MoldWizard.

You used the MoldWizard system to create


region features for core and cavity, then
created associative tooling from each region.

In this lesson you:


 Constructed parting curves.
 Used Traverse Loop to select appropriate
parting curves from system created potential
parting curves.
 Identified transition curves and points.
 Constructed parting surfaces.
 Extracted core and cavity regions.
 Used Enlarge Surface to create a simple
parting.
 Created linked core and cavity models.
 Compared an update model to one used in a
tooling assembly
 Substituted an updated model in a tooling
assembly.

ÏÏÏ
ÏÏÏ
5
ÏÏÏ
ÏÏÏ
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Mold Base

Mold Base ÏÏÏ


Lesson 6
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

PURPOSE In this lesson you will select and add a standard mold
base to a mold project assembly.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Use the Mold Base Management dialog to add a


Standard Mold Base to a two cavity mold insert
assembly.

This lesson includes a review section, within which you will practice family
mold, layout, and custom parting with enlarged surfaces. Additionally, you
will prepare a tooling assembly for the future addition of slides and lifters.

This lesson contains the following activity:

Activity Page
6-1 Adding A Mold Base . . . . . . . . . . . . . . . . . . . . . . . . 6-8

EDS MoldWizard Design Process


All Rights Reserved Student Manual 6-1
Mold Base

ÏÏÏ
ÏÏÏ Mold Base Management
ÏÏÏ
6
ÏÏÏ MoldWizard includes several standard mold base catalogs:

Catalog Metric Inches


DME X X
DME_Interchangeable X
Futaba X
Hasco X
Hasco_E X
Hasco_Interchangeable X X
LKM X
Omni X
Universal X X

Select a moldbase that will accommodate your mold insert from one of these
catalogs. Remember to include allowances for cooling lines, runner systems,
etc.

The Universal moldbase is for designers who need a moldbase plate stack
configuration that is different from any of the standard moldbase
configurations. This is usually done to provide mechanisms for moving parts.

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Mold Base

Selecting the Mold Base icon will open the Mold Base Management dialog:
ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

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All Rights Reserved Student Manual 6-3
Mold Base

ÏÏÏ Catalog
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
The Catalog list À allows you to select the preferred mold base supplier. The
content of this pull down is controlled by a spreadsheet that can be edited using
the Edit Register File button.

NOTE Some catalogs are available in only one of Inch or Metric Units.

À Á

Type

The Type list Á is used to specify a particular type of standard mold base
offered by the supplier, for example 2 or 3 plate Mold. This information is also
controlled by the register file.

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Mold Base

Bitmap
ÏÏÏ
ÏÏÏ
MoldWizard will display a schematic diagram  of the standard mold base for
the selected catalog supplier and type. The diagram is taken from a standard ÏÏÏ
6
ÏÏÏ
bitmap file. You can create your own bitmaps for custom Mold Bases.

Mold Base Index List

This list offers the XY dimensions à available for the selected standard mold
base. The system will determine which choice best suits your layout and offer
that choice as the default, based on Layout Information Ä stored when you use
Layout.

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All Rights Reserved Student Manual 6-5
Mold Base

ÏÏÏ Edit Register File


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Edit Register File Å will open the MoldWizard spreadsheet file where the
selected standard mold base is registered. This edits Mold Base menu choices.

Edit Data Base

Edit Data Base Æ will edit the MoldWizard spreadsheet file where components
of the selected standard mold base are defined.

Æ
Ç
È

Rotate Mold Base

Rotate Mold Base Ç is used to rotate the entire mold base assembly 90 degrees
while keeping the insert layout stationary.

Edit Component

Edit Component È is used to modify a parameter of a component of a mold


base after the mold base has been added to your assembly.

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Mold Base

Customization
ÏÏÏ
ÏÏÏ
As an example, to customize the Universal mold base, you would
ÏÏÏ
6
ÏÏÏ
 Save a copy of the seed assembly
 Modify the assembly or components to your needs
 Add new parameters and choices to the Data Base
 Edit unwanted or modified choices in the database
 Define new pull down Lists as desired (see below)
 Include the new part in your menus via the Register File

Expression List

The mold base Expression List À contains all mold base parameters that may
be edited. The expression that is highlighted in the list will appear for editing
in the Expression Edit Window Á immediately below.

Standard Component Size Lists

The list boxes found in the bottom portion of the dialog  allow easy selection
of standard sizes from drop down lists.

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All Rights Reserved Student Manual 6-7
Mold Base

ÏÏÏ Activity 6-1: Adding A Mold Base


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
In the following project, you will review earlier lessons. Very few details are
given for familiar steps.

À
Â

Ã
Á
Ä

À Upper Case - mdp_mcu


Á Lower Case - mdp_mcl
 Snap (one on each side)
à Snap Seat (one on each side)
Ä Cord Opening

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Mold Base

During this Activity you will work with two pieces of a 3 button mouse assembly
ÏÏÏ
to produce a two cavity family mold with examples of slide and lifter techniques.
ÏÏÏ
The parts are greatly simplified to permit faster load times and faster progress.
Slides and lifters will be added in the standard parts lesson. ÏÏÏ
6
ÏÏÏ

Mold Insert Layout - Upper and Lower Mouse Case

À Upper Case Insert


Á Lower Case Insert

NOTE Verify that Application  MoldWizard is active.

Step 1 Open your mouse project.


 Open .../mouse/mouse_top.
If needed, a staged assembly for this activity is in:
... / moldwizd / mouse_3 /

Step 2 Create a Mold Tooling Insert.


 Set the Work Piece size:
Type:
X_length . . . . . . . . . . . . 175.0
Y_length . . . . . . . . . . . . 125.0
Z_down . . . . . . . . . . . . 56
Z_up . . . . . . . . . . . . . . . 56

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Mold Base

ÏÏÏ  Replace View to TFR-TRI.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ Step 3 Create a single face contour parting.

 Choose MoldWizard Tools  Enlarge Surface.

 Set the Work Layer to 2, and make layer 20 Selectable.

 Select the narrow lip face of the part . . . Â

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Mold Base

 Enable Cut to Boundary, and be sure the As Existing Surface


ÏÏÏ
toggle is enabled (the default condition).
ÏÏÏ
 Rotate the part if necessary and use the insert block in layer ÏÏÏ
6
ÏÏÏ
20 as a visual guide to make the surface larger than the
insert block: enlarge at least 80% in U and 65% in V.

 Choose OK to accept the default trim boundary . . . Ã


and default trim options.

Step 4 Adjust layer options.

 In the Layer Settings dialog, make 1 the Work Layer, and all
others Invisible.

Notice that there is nothing in layer 2, the previous Work Layer.


The option As Existing Surface tells the system to treat the face
created as a core and cavity pair. The original is placed in layer
255, MW_HideObjectLayer. Extracted copies are placed in layers
27 and 28, MW_PartingCoreSurfLayer and
MW_PartingCavitySurfLayer respectively.

Step 5 Prepare core and cavity regions.

 Choose the Parting icon.

 Enable Auto Process.

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All Rights Reserved Student Manual 6-11
Mold Base

ÏÏÏ  Choose Extract Regions.


ÏÏÏ Verify that you have 24 total faces, 4 in the Cavity and 20 in
ÏÏÏ

6 the Core, then choose OK.
ÏÏÏ Step 6 Create, examine, and accept both cavity and core inserts.
Notice that the core part contains undercut areas at the
Snaps".

Step 7 Create a slide head.


Note that mouse_mdp_mcu_core is both the work and displayed
part. In this step, you will create a slide head in this core insert
file.
 Choose the MoldWizard Tools icon.
 Make 10 the Work Layer.
 If necessary, set the Display Mode to Wireframe.
 Zoom in on the area shown in the figure below.
 Create Box using an Allowance of 6.5 millimeters, and the
two shaded faces shown below.

ÄÄÄÄÄ
ÄÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄÄ
ÄÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄÄ
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Mold Base

 Use MoldWizard Surface Split to trim the block using the


ÏÏÏ
five faces shown below.
ÏÏÏ
Remember: The Vector Arrow points toward the side you ÏÏÏ
6
ÏÏÏ
want to remove.

Ã
ÄÄÄÄ Â
Á ÄÄÄÄ
ÄÄÄÄ
ÄÄÄÄ
Ä

Face Split with...


À Top Parting sheet
Á Bottom Lip of snap
 Side adjacent to product Outer face of snap
à Left Side Left side of snap
Ä Right Side Right side of snap

The desired result is illustrated below.

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All Rights Reserved Student Manual 6-13
Mold Base

ÏÏÏ  Use Edit → Object Display to set the partial shading


ÏÏÏ attribute to YES for the small block just created.
ÏÏÏ
6
ÏÏÏ Standard parts, including slides and lifters, are partially shaded.
This solid body is partially shaded because it will eventually
become part of a slide assembly.

Step 8 OPTIONAL: If time permits, create a slide head on the


opposite side of the part.

Step 9 Save your work.

 Make mouse_top the displayed and work part.

 Choose File  Save All.

TIP It is a good idea to save your work before modifying the


project by adding other products.

Step 10 Create a family mold by adding the lower case.

 Use the Load Product icon to add mdp_mcl (mouse case


lower) to your assembly.

 Rotate the WCS 180° about either YC axis (plus or minus).

 Set the Mold CSYS to the Current WCS with the Lock Z
Value checkmarked ON (the default Mold CSYS settings).

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Mold Base

If the WCS is correct the lower case will flip over", but will still
ÏÏÏ
lie on top of" the upper case, as shown below. You will correct
ÏÏÏ
the position in just a moment, using layout.
ÏÏÏ
6
ÏÏÏ

 Enter Shrinkage, Uniform Scale factor 1.005

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All Rights Reserved Student Manual 6-15
Mold Base

ÏÏÏ  Set the Work Piece size, using the previous values:
ÏÏÏ
ÏÏÏ
6
ÏÏÏ
Type:
X_length . . . . . . . . . . . .
Y_length . . . . . . . . . . . .
175.0
125.0
Z_down . . . . . . . . . . . . 56
Z_up . . . . . . . . . . . . . . . 56

When you intend to machine inserts with one or more


dimensions the same, you might create several work pieces to
determine the size needed. You can easily edit various work
pieces to the dimensions you determine.
We supplied values based on our experience in creating the
activity.

 Use Layout → Transform → From Point to Point to create


the arrangement shown below, rounded ends facing together:

Hint: as you transform, you can visually distinguish the end


points of work piece edges easily. Notice that the upper case is
already split into core and cavity, and the lower case is not.

 Use Auto Center to center the inserts about the WCS.

 Cancel the Layout dialog.

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Mold Base

Step 11 Create one patch surface at the cord opening.


ÏÏÏ
ÏÏÏ
Although edges could be extruded to create a parting with a lump" in
it for the cord opening, Product Design Advisor showed us that the ÏÏÏ
6
ÏÏÏ
walls of the opening have no draft. If we were to extrude the edges the
resulting contour would be too susceptible to wear or damage.

For this example we will simply shut off the opening and accept small
undrafted faces in the core.

 Choose the MoldWizard Tools icon.

 Choose Edge Patch.

 Using the illustration below as a guide, select the top of the


left vertical edge . . . . À

 Choose Accept or Next Path as required to select the arc and


opposite vertical edge.

À Á

Â
Â

After the opposite vertical edge Á is accepted, the Traverse Loop


function will highlight one of the lower edges . . Â
When this occurs:

 Choose Close Loop.

The outer face surrounding the opening will highlight and the
status line will read: Found 1 faces to patch up.

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All Rights Reserved Student Manual 6-17
Mold Base

ÏÏÏ  Choose OK to create the patch . . . . Ã


ÏÏÏ
ÏÏÏ
6
ÏÏÏ

Step 12 Create a single contour parting face.


 Make layer 20 Selectable.

 Choose Enlarge Surface.

 Select the face indicated in the illustration below.

 Using the insert block for reference, enlarge about 70% in U


and V.

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Mold Base

 Enable Cut to Boundary.


ÏÏÏ
ÏÏÏ
The desired boundary for this operation is the outer perimeter
of the highlighted face edges. ÏÏÏ
6
ÏÏÏ
NOTE The inner perimeter edges and small edges inside the
cord opening need to be edited out of the boundary
definition.

The following action items will demonstrate a simple way to


define the required boundary.
 Choose Edit Boundary.

 Deselect All the highlighted edges by dragging a rectangle


around the edges with a shift key depressed.

 Select the 6 edges of the outer perimeter.

NOTE Don't forget the small corner radii.

 Choose OK when your edits are complete.

 Choose OK to create the enlarged and trimmed sheet.

 Make/Verify layer 1 the Work Layer, and all others Invisible.

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All Rights Reserved Student Manual 6-19
Mold Base

ÏÏÏ Step 13 Create tooling inserts.


ÏÏÏ
ÏÏÏ
6
ÏÏÏ
 Choose Parting.

 Set Auto Process.

 Extract Regions for core and cavity as before. There should


be 34 faces, 15 in the cavity and 19 in the core.

 Create Cavity.

 Create Core.

Notice that the core insert contains a small undercut in the Snap
area . . À
This will be addressed in the next lesson by adding a lifter.

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Mold Base

Step 14 Save your work.


ÏÏÏ
ÏÏÏ
 Choose File  Save All.
ÏÏÏ
6
ÏÏÏ
Step 15 Add a mold base.

 Choose the Mold Base icon.

Choosing Mold Base automatically changes the displayed part to


mouse_top.

Because the parting is contoured we make a mental note that we will


eventually have to create draft or clearance where insert edges depart
from the parting plane.

 Choose the DME Catalog . . À

 Choose Type 2B . . . . Á

À Á

 Choose the BP_h pull down and select 56 from the list . . Â

Ã
Â

 Choose the AP_h pull down à and select 56 . . Ã

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All Rights Reserved Student Manual 6-21
Mold Base

ÏÏÏ Index size 4545 is automatically selected . . . Ä


ÏÏÏ because you earlier used the Layout dialog. Using Layout saves

ÏÏÏ
6
ÏÏÏ
Layout Information . . Å

TIP An important function of Layout is to save information


about the size of the work piece layout. This enables
automatic mold base index selection.

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Mold Base

 Choose Offset_Fix . . . Æ
ÏÏÏ
ÏÏÏ
 Type .051 in the input window . . Ç
ÏÏÏ
6
ÏÏÏ
 Press Enter.

When you press Enter, the value you typed will appear in the
parameter list . . . È

 Choose Offset_Move . . É

 Enter .051 in the input window . . . Ê

È
É

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All Rights Reserved Student Manual 6-23
Mold Base

ÏÏÏ  Choose OK to accept the remaining defaults and add the


ÏÏÏ moldbase.
ÏÏÏ
6
ÏÏÏ  Adjust the view and examine the mold base.

Step 16 Save your work.


You will use this assembly again in the lesson on standard parts.

 Choose File → Close → Save All and Close .

This concludes Activity 6-1.

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Mold Base

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

SUMMARY This lesson introduced the Mold Base


Management dialog and the process
MoldWizard uses to add a standard mold base
to an existing mold insert layout. The
importance of reviewing and resolving
dimensional differences in the mold base/insert
assembly was mentioned. This lesson also
provided a review on core & cavity extraction
and the process of laying out a two cavity
production mold.

In this lesson you:


 Reviewed previous lessons by building the
mouse assembly.
 Prepared the mouse shrink part for the
future addition of slides and lifters.
 Used the Mold Base Management dialog box
to add a Standard Mold Base to a two cavity
mold insert assembly.

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Mold Base

ÏÏÏ
ÏÏÏ
ÏÏÏ
6
ÏÏÏ

(This Page Intentionally Left Blank)

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Standard Parts

Standard Parts
Lesson 7

PURPOSE You will use the Standard Part Management dialog to add
standard parts to a mold base assembly, including Ejectors
and Sliders and Lifters. You will practice Pocket Creation. ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
OBJECTIVES Upon completion of this lesson, you will be able to:

 Select standard parts from a standard parts catalog.


 Edit standard part parameters and define locating
points.
 Add standard parts to a mold base assembly.
 Create pockets to accommodate the added
standard parts.
 Add sliders and lifters to an assembly.

This lesson contains the following activities:

Activity Page
7-1 Adding Ejector Pins and a Sprue Bushing . . . . . . 7-15
7-2 Post Processing and Pockets . . . . . . . . . . . . . . . . . . 7-33
7-3 Sliders and Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

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All Rights Reserved Student Manual 7-1
Standard Parts

Standard Parts Overview

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Several MoldWizard functions are used for the placement and management of
standard parts," or hardware needed in a tooling assembly.

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Standard Parts

Standard Part Management

Standard mold components are selected from a catalog and positioned within
the tooling assembly. Standard parts can apply to the mold generally, e.g.
locating ring & sprue bushing, or to individual mold inserts, e.g. ejector pins &
ejector sleeves. Some standard parts are automatically located by MoldWizard,
and others require a defined locating point.

ÏÏÏ
ÏÏÏ
7
Ejector Pin Postprocessing
ÏÏÏ
ÏÏÏ
Ejector Pins are selected and positioned using the Standard Part Management
dialog. The Ejector Pin dialog provides postprocessing tools to define the close
fit distance" and to optionally trim ejectors to part contours.

Slider and Lifter

The Slider Lifter dialog provides a specialized set of standard parts, slider and
lifter subassemblies.

Mold Trim

This utility automates commonly needed WAVE linking and feature modeling
tasks to trim a standard part to the core or cavity trim sheet.

Pocket Creation

Once standard parts are selected and positioned within the mold assembly,
pockets, voids, threaded holes, etc. must be created to receive these added
parts.

Pocket Creation is also used with Gates, Runners, and Cooling channels.

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All Rights Reserved Student Manual 7-3
Standard Parts

Other Standard Part Library Functions

Several important functions make Standard Part style libraries available:

 Work Piece

 Sub Inserts
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
 Cooling

 Electrodes

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Standard Parts

Standard Part Management

Catalog Tab

À ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Á

Catalog

The Catalog pull down menu À allows you to select a standard parts catalog
from a list of standard mold part suppliers including: Hasco, DME, Futaba
(Metric only) and Omni (Inch only).

An additional choice, Component_Set, allows adding sub components with


multiple instances in patterns, such as locating screws and springs

Additionally, the catalog list contains a Yates hydraulic cylinder (Inch only).

Only catalog names with corresponding units to your project will appear. It is
important to consider units before beginning a project, with forethought
regarding the Mold Base and Standard Parts catalog you want to use.

Parts List Window

The window immediately below the Catalog window Á lists parts available from
the specified supplier. The number and type of parts listed can be filtered by
using the Classify list described next.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-5
Standard Parts

Classification

The Classification pull down menu  provides a filter to narrow the list of
standard parts that appear in the Parts List Window described previously. The
default setting of All Standards will include all standard parts offered by the
supplier. Other choices under Classify that will narrow this list may include:
Locating Ring and Sprue, Ejector Pin, Locks, Screw, and Other.

ÏÏÏ
ÏÏÏ
7
Â
ÏÏÏ
ÏÏÏ

Ã
Ä

Standard Part Name

The Standard Part Name field à displays the default part file name for a new
instance of the selected standard part. If the part was added previously, the
name will be appended with a unique number. This filename may be edited to
any valid name by editing in the input window . . . Ã

Flip Direction

Flip Direction Ä allows you to flip the normal" direction for a standard part
that is positioned on a plane. The part will move to the opposite side of the
placement plane.

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Standard Parts

Parent

The Parent pull down menu Å allows you to specify the parent component for
added standard part. If the parent you want is not in the list, make it the work
part before you access Standard Parts. The work part is always on the list.

Å
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
Æ

Position

The Position menu Æ allows you to specify the method to be used for
positioning a standard part:

NULL: . . . . . . Origin will be the absolute (0,0,0) of the assembly tree


WCS: . . . . . . Origin will be the current WCS (0,0,0)
POINT: . . . . . Uses X-Y plane with a user selected point as the origin
PLANE: . . . . . Select a planar face as X-Y plane, then select an origin point
MATE: . . . . . . Add the part at any selected point, then position it with mating

True / False / Both


This set of radio buttons Ç controls the reference set to display for standard
parts you are adding. True displays the standard part geometry, False displays
the pocket cutting geometry, and Both displays both sets of bodies at once.

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Standard Parts

Add/Modify
When an existing standard part is selected in the graphics screen, the Add/Modify
toggles will be made available . . . È

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Add will add another standard part that is identical to the selected part.
Modify is used to edit the selected part.

Standard Parameter Lists


The most common dimensional features of the selected part are listed in the
bottom portion of the Catalog tab. Features available here are pre-defined
standard sizes from the supplier.
For more detailed editing choices, choose the Dimension tab.

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7-8 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Dimension Tab

À
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Bitmap

An illustration À depicts the selected standard part and key dimensions.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-9
Standard Parts

Parameter List

A window Á lists all editable values for the selected part. The parameter that is
highlighted in the list appears for editing in the Edit Window Â.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

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7-10 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Lock/Unlock

The main purpose of parameter-locking à is to preserve values when a large


change is made to a mold design in progress, such as a mold base size. Locked
parameters, such as plate thicknesses or screw positions, will not change to the
defaults for the new mold base size.

Ã
ÏÏÏ
ÏÏÏ
7
A locked dimension can only be edited manually. There is a "*" before a
dimension name when it is locked . . Ä ÏÏÏ
ÏÏÏ
Ä

Å Æ

When the selected dimension is locked, the left button will read Unlock . . . . Å

If a dimension is locked, it will be grayed out Ç on the Catalog Tab. Users


cannot change it from an Options list or a slider bar.

Unlock All

Unlock All Æ is, as the name implies, a rapid method to unlock all locked
parameters for the selected standard part.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-11
Standard Parts

Operation Tab

Edit Register File / Data Base

These buttons ÀÁ will open a MoldWizard spreadsheet file for the standard
part library. The register spreadsheet controls what parts appear in the menu,
classifications available, bitmaps, parameters in the list box, and pull down
parameter lists. The Data Base spreadsheet can edit parameters, attributes,
and other data related to the selected standard part.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
À
Á
Â
Ã

Remove Component

Remove Component  removes selected standard parts from the assembly.

Reposition

Reposition à allows you to reposition selected standard parts within the


assembly via translations, rotations, and point to point movements.

TIP If you reposition ejector pins, or any standard parts which have
relationships with the moldbase, such as locating rings and
lifters, don't move the Z value, because the Z level distances are
controlled by MoldWizard relationships.

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7-12 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

TIPS
When you add a standard part, it is recommended
to set the Partially Shaded option as the Display
Mode. MoldWizard Standard Parts have the parĆ
tially shaded attribute set.

You need to set Assemblies_AllowInterPart: yes in


the ug_metric.def or ug_english.def file.

ÏÏÏ
Make sure not to turn on Delay Interpart Updates

ÏÏÏ
default in UG Assemblies module section of the
defaults files. 7
If the system is in the Assembly Parts List or the
ÏÏÏ
ÏÏÏ
Drafting application, switch to the Modeling apĆ
plication.

Clearance values ("clr" in expression name) default


to zero. If clearance is desired, look for and edit
these expressions. Clearance expressions affect the
corresponding pocket creation body.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-13
Standard Parts

Tip for Opening Large MoldWizard Assemblies

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

From this point in the class onwards, tooling assemblies you open may have
many members.

On Windows systems, you can avoid having to search a scrolling list for the top
part.

In the Windows Open Part File dialog, enter File name *top.prt" (without
quotes) and press Enter.

The file list will be filtered to only the top level part, as shown above.

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7-14 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Activity 7-1: Adding Ejector Pins and a Sprue Bushing

In this activity you will add Ejector Pins and a Sprue Bushing to the two cavity
tray mold assembly.

One Ejector Pin exists for each cavity . . À

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
À

Each cavity requires four Ejector Pins.

As these instance specific pins are created, they will automatically


appear in all instances of the mold cavity.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open your mdp_tray_top tooling assembly.


If needed, a staged assembly for this activity is in:
... / moldwizd / tray_2 /

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-15
Standard Parts

Step 2 Set the display to a TOP view.

Step 3 Add three Ejector Pins.

 Select the Standard Parts icon:

 Verify that the Catalog is Hasco.

ÏÏÏ
ÏÏÏ
7
 Change the Classification field to Ejector Pins.

ÏÏÏ
ÏÏÏ
The work part changes from the tray_top assembly to the parent
tray_prod part and one cavity highlights.

 Zoom In on the highlighted cavity:

 Select the existing Z41 pin from the screen . . Á

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7-16 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

 Choose Add to create new instances of the same part . . . Â

ÏÏÏ
ÏÏÏ
7
Ã
ÏÏÏ
ÏÏÏ

 Set the Position Method to Point . . . Ã

 Choose Apply.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-17
Standard Parts

The Point Constructor dialog displays to aid in locating the


ejector pin.

 Choose the Arc/Ellipse/Sphere Center icon.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
 In the graphics screen, select the arc edge shown below:

 Cancel the Point Constructor dialog.

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7-18 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

The Standard Part Management dialog displays.

NOTE Each of the three new Ejector Pins must be moved 5mm
in the Y direction. One pin also needs adjustment in the
X direction. A drawing is provided.

You will adjust each pin as you add it.

 Choose the Operations tab.

 Refer to the drawing below for positioning information: ÏÏÏ


ÏÏÏ
7
ÏÏÏ
ÏÏÏ
1.000

5.000

NOTE The 1.000 offset in X applies only on the side adjacent to


the sharp corners of the tray.

 Zoom in to observe an target ejector pin and its location.

The most recently added ejector pin should still be selected. Use
screen selection to pick it if necessary.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-19
Standard Parts

 In the Standard Part Management dialog, select the


Reposition Part button. The Reposition dialog opens.

 Enter 5.0 in the Y entry field to locate the top ejector pin,
and select OK.
Use -5.0 when appropriate.
 Enter plus or minus 1.000, as appropriate, in the X window
for pins located near the back (sharp corners) of the tray.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

The ejector pin moves to the correct location and the Standard
Part Management dialog reappears.

 Return to the Catalog tab.

 Verify that an ejector pin is still selected, and that the Add
option is still active.

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7-20 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

 Add two more Ejector Pins by first selecting, then confirming


the two arc edges shown below:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 After all three pins have been added and reĆpositioned,


Cancel the Standard Part Management dialog.

 Use Assembly Navigator to make tray_top the work part (if


necessary).

 Go to a Trimetric view by clicking MB3 then choosing


Replace View  TFR-TRI from the pop-up menu.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-21
Standard Parts

 Partially Shade the view by clicking MB3 then choosing


Display Mode  Partially Shaded.

Standard part bodies have their Partially Shaded" attribute set


to Yes." This enables you to easily visualize standard parts
placement relative to a wire frame mold base assembly.

Examine the mold assembly and the new instances of the


ÏÏÏ

trimmed ejector pin that have been placed.
ÏÏÏ
7
ÏÏÏ
ÏÏÏ NOTE If the pins required different trim, we could not have
used the instancing method. A new pin component is
required for at least one instance of every unique trim
configuration.

Step 4 Add a Sprue Bushing.

 Choose the Standard Parts icon.


 From the HASCO Catalog, choose
Classification  Sprue . . À
 Locate and select Z512 (Sprue Bushing) . . Á
 Edit the parameters. Refer to the illustration if necessary.

Sprue Type . . Sphere . . . . . . Â


d2 . . . . . . . . . . 18 . . . . . . . . . . Ã
d1 . . . . . . . . . . 4 ........... Ä
l ............ 66 . . . . . . . . . . Å
sr . . . . . . . . . . . 15.5 . . . . . . . . Æ

 Choose Apply . . Ç

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7-22 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

Â
Ã
Ä
Å
Æ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-23
Standard Parts

The sprue bushing is automatically aligned with the top center


of the moldbase. The standard length provided may or may not
be correct for the assembly.
We chose a centering ring that is recessed 4mm below the top of
the upper plate. The lower end of the standard length sprue
bushing extends 1mm into the moving half.
You could verify this information, optionally, using
AnalysisĂÕĂDistance.

ÏÏÏ
ÏÏÏ
7
 Choose the Operation tab.

ÏÏÏ
ÏÏÏ
The sprue bushing should still be selected.

 Choose Reposition.

 Enter -4.000 in Z, and then choose OK.

The bushing is now correctly aligned with the centering ring;


however, the other end now extends into the moving half by
5.0mm.

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7-24 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

 Choose the Dimension tab . . . À

 Select the line for l in the list . . Á

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Edit the value of l to 61.0 . . . Â


Hint: Do not forget to press Enter.

 Choose OK.

This concludes Activity 7-1.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-25
Standard Parts

Ejector Pin Post Processing


The Ejector Pins initially added to a mold assembly will be of a standard length
and shape. Ejector Pin Post Processing refers to the steps that are taken to
modify a pin's standard length and shape to match the specific size and shape of
an individual mold and product part design.

Selecting the Ejector Pin icon will open the Eject Pin Post Processing dialog:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ Select

Trim Methods Display Options

Trim Surfaces Fit Distance

Trim Methods
MoldWizard offers two ejector pin trim options, and the ability to Untrim.

Display Options
Display options control the display of the ejector pins and their corresponding
pocket bodies.

Trim Surfaces
Controls the surface to which ejector pins are trimmed.

Fit Distance
Fit distance or land refers to the length of tight tolerance fit that is to be held at
the tip of the ejector pin where it erupts from the core face.

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7-26 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Trim Methods

Adjust Length
This trim method adjusts the length of the ejector pin to the highest Z level of
the pocket opening on the surface of the core body.

Note how this trim method will leave a pronounced knockout mark or
indentation in the molded part.

ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
À ÏÏÏ
ÏÏÏ
7
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÏÏÏ
ÍÍÍÍÍÍÍÍÍÍ ÏÏÏ
ÍÍÍÍÍÍÍÍÍÍ
 ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
Ã
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
Á
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
À Cavity Steel
ÍÍÍÍÍÍÍÍÍÍ
Á Core Steel
 Pocket where plastic will flow
à Highest Z level of pocket opening

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-27
Standard Parts

Sheet Trim
This trim method contours the end of the ejector pin to match the core surface.

Note how this trim method will not leave a pronounced knockout mark or
indentation in the molded part.

ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
À
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÏÏÏ
ÏÏÏ
7
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÏÏÏ
ÏÏÏ
 ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
Á
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
ÍÍÍÍÍÍÍÍÍÍ
À Cavity Steel
Á Core Steel
 Pocket where plastic will flow

Untrim
This option is used to remove the trim from an ejector pin.

Display Options
The Display Options of True, False and Both control the reference set display
of Ejector Pin components. These options will be discussed in detail in the next
section on Creating Pockets.

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7-28 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Trim Surfaces
Ejector Pins must be trimmed to the final parting face of the core body.

Given that the final parting face of the core body may not always be the initial
parting face defined by the Parting Surface, a second option called Mold
Surface is provided.

Parting Surface
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
The Parting Surface option should be used when the parting sheet sets found in
the parting component" À are suitable to trim the target pin Á.
ÏÏÏ
This is the same sheet that was copied to trim the core body.

Á
À

Mold Surface

The Mold Surface option should be used when the parting sheets that formed
the core À are not suitable to trim the ejector pin Á. In this method, a region is
extracted from the core body into the parting part and this region will be used
to trim the ejector pin.

Example: a solid patch  was used to add material to the initial parting face of
the core body. Use Mold Surface.

À Á

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-29
Standard Parts

Fit Distance
Fit distance or land refers to the length of tight diametric tolerance that is to be held
at the tip of the ejector pin where it erupts from the core face.

This tight tolerance is used to create a seal to prevent excessive flashing, yet
allow enough room for venting and free movement with minimum mold wear.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

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7-30 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Pocket Creation

After you add and position all standard parts, gating, and cooling lines, the last
step to complete your mold assembly is Create Pockets.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

MoldWizard will create pockets for any standard part that has been created
using the following convention. The standard part must contain a FALSE"
reference set comprised of a tool body to subtract from various mold plates to
create the necessary pocket. The part must also contain a TRUE" reference set
comprised of the solid bodies for the standard part.

Internally, the FALSE body of the standard parts is linked to the target body
parts, and is subtracted from the target body.

We strongly recommend that you use Create Pockets function at the last stage of
mold design. There are two reason for this:

 First, after cutting the pockets, update performance will slow down
due to the presence of WAVE linked bodies for each pocket.

 Second, mold base updates could fail if standard parts fall outside a
previously selected pocket target body.

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All Rights Reserved Student Manual 7-31
Standard Parts

There are five methods provided to create pockets. The mold_defaults file
controls which method will be your default, by MW_PocketMethod.

Target + Standard

Special procedure for Target + Standard:

 When the dialog first opens you select a target body or bodies.

ÏÏÏ
ÏÏÏ
7
 Choose the OK or Apply button
A Selection dialog appears.
ÏÏÏ


ÏÏÏ  Proceed to select standard parts for which pockets are required.
 Choose OK in the selection dialog to end part selection and create
pockets in the target bodies.

Target Body

This option allows you to select mold base plates or any part that is not a
standard part," such as the core and cavity work piece inserts. When you
choose OK or Apply MoldWizard will find all intersecting standard parts and
cut pockets automatically.

Standard Part

This option will allow you to select standard parts only. After you select the
standard parts, choose the OK or Apply. MoldWizard will find all mold base
plates intersecting with them and will cut pockets automatically. Only plates
which are not blanked and are on the visible layer will be cut.

TIP Blank the fixed half of the mold base assembly before you use
Standard Part cut pockets for ejector pins. Only movable half plates
will be found and cut with pockets.
In general, the system will use only bodies which are selectable as
targets for pocket cutting.

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7-32 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Activity 7-2: Post Processing and Pockets

In this activity you will add more pins, and create pockets for standard parts.

NOTE Verify that Application  MoldWizard is active.

ÏÏÏ
ÏÏÏ
7
Step 1 Open your mdp_tray_top tooling assembly.
If needed, a staged assembly for this activity is in:
ÏÏÏ
ÏÏÏ
... / moldwizd / tray_3 /

The tray feet" are long, thin sections with very little draft.

Adjacent ribs have no draft.

If the design must be used as modeled, it might be prudent for each


boss to have an individual ejector pin.

Notice that all feet are the same length. This fortunate consequence of
intelligent design enables us to instance a single component pin.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-33
Standard Parts

Step 2 Add a new size ejector pin one tray boss.

 Choose Standard Parts, Hasco . . . À, Ejector Pins . . Á

À
Á

ÏÏÏ
ÏÏÏ
7
Â
ÏÏÏ
ÏÏÏ
Ã

 Choose Z41 (Ejector Pin, Cylindrical) . . . Â

 Verify that the Position method is POINT . . . Ã

 Change pin_d to 2 . . Ä

 Choose OK.

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Standard Parts

The Point Constructor appears.

 Choose Arc/Ellipse/Sphere Center.

 Select the circular edge of any one foot.

 When the pin has appeared, choose Cancel.

Step 3 Post Process the new ejector pin.

ÏÏÏ
ÏÏÏ
7
 Choose the Ejector Pin icon.
ÏÏÏ
ÏÏÏ

The Eject Pin Post Processing dialog displays.

 Verify the default options shown.

 Select the new ejector pin just added.

 Choose OK in the Eject Pin Postprocessing dialog.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-35
Standard Parts

Step 4 Create three new instances of the trimmed pin.

 Choose the Standard Parts icon.

 Select the new 2mm diameter ejector pin.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
À

 Choose Position POINT . . À

 Choose Add . . . Á

 Choose OK in the Standard Parts dialog.

The Point Constructor appears.

 Choose Arc/Ellipse/Sphere Center.

 Continue to select each foot, until all four feet have one
adjacent ejector pin.

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7-36 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Step 5 Create Pockets in mold plates for the Ejector Pins and
sprue bushing.

 Choose the Create Pockets icon:

ÏÏÏ
ÏÏÏ
7
The Create Pockets dialog displays.
ÏÏÏ
ÏÏÏ

 Choose the Standard Part option . . À

NOTE The next instruction assumes that two of the sixteen pins
already have pockets from an earlier activity.

 Select the six 4.5mm pins that do not have pockets, all eight
2mm pins, and the sprue bushing.

 Choose Apply.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-37
Standard Parts

Step 6 Create Core Body Pockets for the Ejector Pins.

 Choose Target + Standard . . . Á

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Select a core insert.


Hint: The status reads Solid Body: UM_CORE_BLOCK."

 Choose OK.

NOTE The next instruction assumes that one of the eight pins
already have pockets from an earlier activity.

 Select all 7 pins without pockets that intersect the insert.

Step 7 Create a sprue bushing pocket in the cavity insert.

 Choose Create Pockets  Target + Standard.

 Select either cavity insert, UM_CAVITY_BLOCK.

 Choose OK.

 Select the Sprue Bushing.

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7-38 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

 Choose OK to end selection.

MoldWizard creates a pocket in the cavity workpiece for the


sprue bushing.

 Choose File  Save All.


 Examine the mold assembly.

ÏÏÏ
TIP You can use Blanking to verify pockets.
Select only the component you are interested in, and
ÏÏÏ
7
then choose All But Selected, OK.
ÏÏÏ
ÏÏÏ
 Replace View with Tfr-Tri.

 If necessary, Unblank everything.


Hint: Ctrl-Shift-U

Step 8 Choose File  Close  Save All and Close.

You will use this assembly again.

This concludes Activity 7-2.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-39
Standard Parts

Sliders and Lifters

MoldWizard's Slider / Lifter function uses Standard Part Management to


provide an easy way to design the sliders and lifters you need.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

MoldWizard Design Process EDS MoldWizard V18.0.3


7-40 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Slides and lifters have two main parts: head and body. The head is dependent
on the product shape. The body is composed of customizable standard parts.

À Á ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
à Å
Å
Â
Â

Ä
Æ

Push-Pull Slider
À Cam Drive Unit
Á Attach Tool Section (Head) here
 Retainers
à Slide
Ä Baseplate
Å Drive faces of Cam unit
Æ Direction of Slider motion
Ç Direction of mold plate motion

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-41
Standard Parts

Head Design

There are two ways to create slider or lifter heads: Solid Head and Trim Body.

Solid Head

The solid head method is often used in slider head design. To use the solid
method to create a slider or lifter head, the Solid Split discussed on page 3-39 is

ÏÏÏ
ÏÏÏ
7
ideal.

ÏÏÏ
 Create the head body in the core or cavity.

ÏÏÏ  Add the appropriate slider or lifter.


 WAVE link the head body into the slider or lifter body part.
 Unite the head with the body.

Alteratively, you can create a new component and link the head to the new
component. This alternative is preferable if the piece will be machined
separately and assembled with fasteners.

Trim Body

To use the trim body method:

 Add a slider or lifter to the mold base.


 Use Mold Trim trim a selected body with the core or cavity trim sheet.

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7-42 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Slider and Lifter Sub Assembly Structure

Slides and Lifter mechanisms will be added as sub assemblies. Each sub assembly
contains the head, gibs, slides, dowels, or guides necessary to provide the desired
motion.

Lifter Sub Assembly


(Component of Product Sub Assembly)

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

MoldWizard places the lifter sub assembly inside the product assembly.

Slides and lifters pertain to a particular product; therefore, they are collected
under the product part instead of under the misc sub assembly.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 7-43
Standard Parts

Orientation of Slides and Lifters

The YC axis of the WCS must be oriented along the direction of head motion,
with YC+ pointing toward the undercut area of the cavity wall.

The bitmap for each supplied assembly shows the YC+ direction À, origin Á,
and parting line Â. Use this convention if you design custom slides or lifters.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ Á Â Á
À

The slider or Lifter XC-YC origin will coincide with the WCS origin and the Y
axis will be aligned with the YC+ axis. MoldWizard will match the parting
position to the tooling regardless of the current ZC 0.0 location.

Several standard parameters, including standard angles, may be chosen from


selection lists on the Catalog tab.

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7-44 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

Activity 7-3: Sliders and Lifters

In this activity you will add Slides and Lifters to the two cavity family mold in
the mouse project.

NOTE Verify that Application  MoldWizard is active.


ÏÏÏ
ÏÏÏ
7
Step 1 Open your mouse project.
ÏÏÏ
ÏÏÏ
 Open mouse / mouse_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / mouse_4 /

Step 2 Add lifter(s).

 Set the Display Mode to Partially Shaded.

 Set or verify layer 1 as the Work Layer.

 Choose the Slider Lifter icon: .

The Slider / Lifter Design dialog opens.

NOTE In the following steps, please be very careful not choose


OK or Apply until instructed to do so.

Several steps of preparation are necessary before you Apply.

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All Rights Reserved Student Manual 7-45
Standard Parts

 Choose Dowel Lifter from the list . . . À

ÏÏÏ
ÏÏÏ
7
À

ÏÏÏ
ÏÏÏ  Choose the Dimension tab . . . Á

 Scroll if necessary, and choose riser_top . . . Â

Ã
 Edit the riser_top value to 13 . . . Ã
Hint: Do not forget to press Enter.

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Standard Parts

 Zoom in on the snap area of the lower mouse case.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

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All Rights Reserved Student Manual 7-47
Standard Parts

 Locate the WCS at the center control point of the linear


edge of the snap seat, as shown below:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
 Rotate the WCS 180 degrees about the Z Axis, into
orientation shown above.

How Does it Work?

Z location of the WCS is irrelevant. The lifter will be placed at


the origin of the WCS with respect to X and Y coordinates. The
base Z position will be located correctly to the mold plate.

 Choose OK in the Slider / Lifter Design dialog.

The Dowel Lifter is added to the mold assembly.

 Fit the Display.

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Standard Parts

A right view of the lifter top (shown) reveals that if the lifter were
trimmed at the current location, the head would have a small area of
contact with cavity steel . . À

We can avoid that contact by repositioning the lifter 2.0 mm along the
YC axis . . . Á

A 2.0mm adjustment was determined using Analysis Õ Distance.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
À

2.0 mm

Step 3 Reposition the lifter.

 Orient the view to Right, and zoom in as shown above.

 Choose the Slider Lifter icon.

 Select the lifter on the graphics screen.

 Choose the Operation tab.

 Choose Reposition.

 Enter a Y value of 2.0, then press Enter.

The lifter moves to the position shown by dashed lines in the


illustration.

 Choose OK.

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Standard Parts

Step 4 Trim the lifter head to match the core contour.

 Choose the Mold Trim icon:

The Mold Trim dialog opens:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Select the yellow body of the lifter from the graphics window.

 Choose OK in the Mold Trim dialog.

The lifter is trimmed in the product model. A trim direction


confirmation dialog appears:

 If the trim direction is good, choose OK.

 Choose File  Save All.

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Standard Parts

Step 5 Optional: If time permits, create another lifter on the


opposite side of the part.

TIP When locating the WCS for the second lifter, the default
absolute orientation will be correct. Do not rotate the
WCS when adding the second lifter.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 When the second lifter is finished, choose File  Save All.

Step 6 Activate the Upper Case product.

 Select the Family Mold icon.

 Double-click on mdp_mcu.

 Make Layer 1 the Work Layer, and 10 Selectable.

 If necessary, set the Display Mode to Partially Shaded.

The small block(s) created in the snap area of the upper case is
now shaded in the display.

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Standard Parts

Step 7 Create a slider.

NOTE In the following steps, please be very careful not choose


OK or Apply until instructed to do so.

Several steps of preparation are necessary before you Apply.

 Choose the Slider Lifter icon.

ÏÏÏ
ÏÏÏ
7
 Choose Push-Pull Slide in the list box.

ÏÏÏ
ÏÏÏ
 Choose the Dimension tab.

The default slider width, 50mm, is significantly larger than the


6mm undercut width of the snap.

 Edit the parameter wide to 25.


Hint: Do not forget to press Enter.

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Standard Parts

The origin of the slider needs to be positioned at the edge of the


workpiece, in line with the small block that will form the undercut
portion.

Before adding the slider, the WCS needs to be moved to this precise
position.

 Set the Display Mode to Wireframe.

 Zoom in on the snap area and locate the WCS on the small
block as shown below.
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

The WCS origin is now correct in the XC-ZC plane, but needs
to be moved back along the YC axis to the edge of the
workpiece.

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Standard Parts

 Determine the YC distance from the WCS Origin to the


Edge of the Workpiece using Analysis  Distance.

ZC

ÏÏÏ
ÏÏÏ
7
YC

ÏÏÏ
ÏÏÏ
XC

The YC distance should be roughly 26.2026... millimeters.

 Move the WCS Origin -26.2026... in the YC direction so it


aligns with the edge of the workpiece.

Hint: Use copy/paste to copy the exact distance from YC


Information into the Point Subfunction dialog Y window.

TIP If you happen to leave the Information window open, a


listing of slider parameters will appear in that window
when you choose OK. Parameters of a great many
MoldWizard operations are displayed in the same way.

 Cancel the Point Subfunction dialog. The Slider Lifter


Design dialog reappears.

 Choose OK.

The slider is added.

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Standard Parts

Step 8 Wavelink the body of the slider to the small block that
forms the undercut.
 Window to mouse_mdp_mcu_prod.

 Make layer 10 Selectable to see the small block that forms


the undercut.

 Use the Assembly Navigator to set the Work Part to


mouse_mdp_mcu_core.

 Dismiss the Assembly Navigator window.


ÏÏÏ
ÏÏÏ
7



Choose Application  Assemblies.

Choose Assemblies  Wave Geometry Linker...


ÏÏÏ
ÏÏÏ
The WAVE Geometry Linker dialog opens.
 Choose the Body filter . . À

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All Rights Reserved Student Manual 7-55
Standard Parts

 Select the slider body . . Á

Á
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Choose OK in the WAVE Geometry Linker dialog.

Step 9 Create a Solid Body that will form the Head of the Slider.

The finished design will include a Slider Head that will be fastened to
the face of the slider.

This Slider Head will be created by extruding a solid body from the
nearby face of the just linked slider body, and uniting this new body
with the small solid that forms the undercut.

 Use the Assembly Navigator to set the Displayed Part to


mouse_mdp_mcu_core.

 Dismiss the Assembly Navigator window.

 Set the Display Mode to Wireframe.

 Choose Application  Modeling.

 Make layer 1 the Work Layer.

 Choose Insert  Form Feature  Extrude...

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The Extruded Body dialog opens.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Choose Solid Face . . À

 Select the front face of the slider . . Á

 OK your selection.

The initial Extruded Body dialog again displays.

 Choose OK again.

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Standard Parts

The Extruded Body Method dialog displays.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
 Choose Trim To Face/Plane . . . . Â

The Vector Constructor dialog opens.


A vector arrow displays, pointing away from the slider, toward
the small block that will form the undercut.

 Choose OK in the Vector Constructor dialog to accept the


vector direction.

The Trimming Face dialog opens.

 Choose Extend Trim Face . . . Ã

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Standard Parts

 Select the opposing face of the small block . . Ä

Ä
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
 Choose OK . . Å

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All Rights Reserved Student Manual 7-59
Standard Parts

 The Extruded Body Parameters dialog opens.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ Æ
 Choose OK again to accept the default zero offsets . . Æ

The Boolean Operation dialog displays.

 Choose Unite . . . Ç

 Cancel the Extruded Body dialog.

 Choose File  Save All.

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Standard Parts

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
The face of the slider provided a convenient profile for extruding this
initial Slider Head design . . . . È

The Slider Head is currently much bigger than necessary. The upper
part extends into the cavity. The lower part need not extend into the
guide slots.

In the interest of time we will omit fastener design.

Step 10 Offset the bottom of the Slider Head -19mm.

 Choose Insert  Feature Operation  Offset Face...

The Offset Face dialog opens.

À
Á

 Set the Offset Value to -19 . . . À

 Choose OK . . Á

The Offset Face Method dialog opens.

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All Rights Reserved Student Manual 7-61
Standard Parts

Choose Offset Faces . . . Â


ÏÏÏ


ÏÏÏ
7 The Offset Face Select dialog opens.
ÏÏÏ
ÏÏÏ  In the graphics screen, select the bottom face of the slider
head . . . Ã

 Choose OK.

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The bottom of the Slider Head is offset upwards 19mm.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Cancel the Offset Face dialog.

 Choose Edit  Object Display...

 Select the Slider Head.

 Set Partially Shaded to Yes . . . Ä

Å
 Choose OK . . Å

 Choose File  Save All.

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Standard Parts

Now that the Slider Head has been created, material needs to be
subtracted from the Core Block to generate the space it will occupy.

Step 11 Subtract the Slider Head volume from the Core Block.

Choose the MoldWizard Tools icon.


ÏÏÏ


ÏÏÏ
7 The Tools dialog opens.
ÏÏÏ
ÏÏÏ

 Choose Subtract . . . À

The Select a Solid dialog opens.

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 In the graphics screen, select the Core Block as the target


solid to subtract . . Á

The core block highlights.

 ÏÏÏ
ÏÏÏ
7
Á ÏÏÏ
ÏÏÏ

 In the graphics screen, select the Slider Head as the tool solid
to subtract . . . Â

Material for the Slider Head is removed from the Core Body.

 Cancel the Tools dialog.

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Standard Parts

Step 12 Examine the Slider, Slider Head and Core Body interface.

 Set the Display Mode to Shaded.

Notice how the material on the slider head extends above the
core parting surface into the cavity . . . Ã

Ã
ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

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Step 13 Trim the slider head to the parting surface.

 Choose the Mold Trim icon.

The work part changes to mouse_mdp_mcu_prod.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 In the graphics screen, select the Slider Head.

 Choose OK . . À

 If the trim direction is good, choose OK.

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When finished, the Slider, Slider Head and Core Body in the
product part should appear as shown below:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

 Window to mouse_mdp_mcu_core.

 Choose Format  Move to Layer...

 Move the wave linked slider and the untrimmed parent


Slider Head body to Layer 255.

 Window to mouse_top.

 Choose File  Save All.

Step 14 OPTIONAL: If time permits, add a Slider and Slider


Head to the opposite side of the part.

NOTE The WCS must be positioned to the small block and


rotated 180 degrees about the +ZC Axis before adding
the opposite side slider.

 If you performed the optional step, choose File  Save All.

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Standard Parts

Step 15 Create pockets for the lifter(s) and slider(s) in the


moldbase.

 Set mouse_top as both the displayed and work part.

 Choose the Create Pockets icon:

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
The Create Pockets dialog displays.

 Choose Standard Part . . À

 In the graphics screen, select any component of the slider(s)


and any component of the lifter(s)

MoldWizard will highlight an entire lifter or slider sub assembly


once you select and confirm any component of it.
 Choose OK to create pockets in all of the mold base plates
that intersect the slider(s) and lifter(s).

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All Rights Reserved Student Manual 7-69
Standard Parts

 Choose File  Save All.

NOTE You already created a pocket(s) for the Slider Head(s) in


the upper case core body using Tools Õ Subtract.

Step 16 Create a pocket(s) in the lower case core body for the
lifter(s).

Choose the Create Pockets icon.


ÏÏÏ


ÏÏÏ
7 If necessary, choose Target + Standard . . . À
ÏÏÏ


ÏÏÏ
À

The cue line reads Select Target Bodies, then Standard Parts."

 In the graphics screen, select and confirm the UM_CORE


BLOCK as the target body.
Hint: The lower half of the mold insert nearest the lifter.

 Choose OK.

The class selection dialog appears.


The cue reads Select Standard Parts."

 Select and confirm any part of the lifter, or both lifters if two
are present.

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 Choose OK.

 Choose File  Save All.

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

mouse_mdp_mcu_core with slider pockets

mouse_mdp_mcl_core with lifter pockets

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All Rights Reserved Student Manual 7-71
Standard Parts

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ

mouse_top with sliders and lifters

 Choose File → Close  Save All and Close.

This concludes Activity 7-3.

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7-72 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Standard Parts

SUMMARY This lesson introduced the Standard Part

ÏÏÏ
Management dialog window and discussed the

ÏÏÏ
process of Adding Standard Parts to the mold
base assembly. The process of Pocket Creation 7
and the editing of a Standard Part Bill of
Material was also covered in this lesson.
ÏÏÏ
ÏÏÏ
In this lesson you:
 Selected standard parts from a standard
parts catalog.
 Added standard parts to a mold base
assembly.
 Edited standard part parameters and
defined part locating points.
 Created pockets to accommodate the added
standard parts.
 Added slides and lifters to a family mold
assembly.

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Standard Parts

ÏÏÏ
ÏÏÏ
7
ÏÏÏ
ÏÏÏ
(This Page Intentionally Left Blank)

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Sub Inserts

Sub Inserts
Lesson 8

PURPOSE Many molds have high wear areas or sections that can
be machined conveniently if a separate block or
cylinder of steel is introduced. MoldWizard provides
the Sub-Insert function to rapidly design and place
auxiliary pieces in the tooling assembly.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Define and position Sub-Inserts as required.


ÏÏÏ
ÏÏÏ
This lesson contains the following activities. ÏÏÏ
8
ÏÏÏ
Activity Page
8-1 Sub-Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-1
Sub Inserts

Sub-Inserts

Sub-inserts are used in areas on the core or cavity where:

 intensive wear and tear occurs


 machining is easier to perform on a separate body

A complete Sub-Insert is made up of:

 a head, the contoured section that forms part of the product


 a foot, the section that is attached or bolted into the assembly

Methods of Working

MoldWizard provides two methods of creating sub-inserts:

ÏÏÏ
ÏÏÏ
 Standard Part, the more recent and preferred construction method

ÏÏÏ
8
ÏÏÏ
 Envelope, a legacy construction method

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Sub Inserts

Standard Parts as Sub Inserts

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

The benefits of using standard parts as sub-inserts are:

 sub-components may be attached


 pocket-cutting bodies may be included with detailed features
 The position of the sub-inserts is relative to the Product Model
 The cavity or core shape is applied via the familiar mold-trim function

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All Rights Reserved Student Manual 8-3
Sub Inserts

Envelope Method
NOTE The core and cavity must be created before a sub-insert
component.

Envelope
When you choose Envelope the dialog
shown at the right appears.

Working Part
Create a sub-insert in either the core
or the cavity.
Parent geometry for the sub-insert
component is defined in the part
selected.
ÏÏÏ
ÏÏÏ Working Part selection is available in all

ÏÏÏ
8
ÏÏÏ
three dialogs of the Envelope method.

Create/Edit
Radio buttons govern whether you will
be prompted to select geometry for a
new Envelope or edit an existing one.

Definition Method
Extremity Faces - the same method as
used for Create Box in the Tools dialog.
Dimensions - you specify box or cylinder
dimensions, then position the body
relative to the WCS by typing numeric
input or using dynamic sliders.

Shape
The Envelope can be a box or a cylinder. You may also create the sub-insert by
profile split, a Tools button you practiced using in an earlier activity.

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Sub Inserts

Head

Forming Method
There are four forming methods:
 Trim by Parting Surface
 Trim by Sheet
 Trim by Solid Face
 Intersection

Selection Steps
There are two steps:

Select Envelope - choose an Envelope


to trim.
Select Tool Objects - select trimming
ÏÏÏ
objects or an intersection tool body.
ÏÏÏ
Extrude Edges to Sheet
ÏÏÏ
8
ÏÏÏ
A tool kit allows you to remove unwanted sections of the head by extruding
edges and trimming.
You are prompted to select a start edge. The system displays a cone head vector
indicating the direction it will search for the next edge, and the following dialog:

If you want only one edge, choose Selection Complete. If you want to traverse
more edges, choose either Accept the direction, or Flip the direction, which ever
is appropriate.

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Sub Inserts

When you select a second and subsequent edges, the following dialog is active:

The dialog is similar in function to Traverse Loop. If you choose Selection


complete only edges that were previously accepted will be used. The currently
highlighted edge is not used.

When you finish defining a series of edges, you will be presented with the
Vector Constructor to define an extrusion direction, and the dialog below to
ÏÏÏ define a distance:
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

The sheet constructed may then be selected in Method  Trim by sheet by


choosing the selection step Select Tool Objects.

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Sub Inserts

Foot

The Foot dialog creates a foot or body,


the part of the insert that is fastened to
a mold plate or main insert block.

This step is critical to the management


of sub-insert components. It is in this
final step that a sub-insert component
and linked geometry are created.

You can create an arbitrary insert using


MoldWizard Tools, such as Profile Split
or Solid Split, then use only the foot step
of Sub-Insert Design to complete the
design and create a separate component
part.

ÏÏÏ
Sub-insert Part Name
ÏÏÏ
The default name is based on the project, ÏÏÏ
8
ÏÏÏ
product, and the current work part. You
may over ride the default by entering a
different name in the Sub-insert Part
Name window.

Create/Edit

Select geometry for a new Foot or edit


an existing one.

Selection Steps

Attach Face (on Head) - The system will


prompt you to select an attachment face.

Mounting Face (on Cavity) - the system


prompts you to select a planar face on
the work piece.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-7
Sub Inserts

Parameter Entry

A set of dimensions for the foot, based on the head size, are displayed in the
expression list. A selected entry from the list may be edited in the text window
below the list.

Foot List

A list of existing sub-insert Foot components allows you to easily select one for
editing.

Copy Sub-insert Component

The Copy Sub-insert Component button creates a new instance of any


previously defined head / foot component. You will be prompted to specify a
position for the new instance.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

Delete

Delete allows you to Delete a selected sub-insert component.

Edit Register File, Edit Database

The Register File is a spreadsheet to control a selection list, in the case the Foot
list. The Database is a spreadsheet which controls the parameters of foot parts
which appear in the list.

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Sub Inserts

Activity 8-1: Sub-Inserts

In this activity you will create sub inserts for the small cylinders that form screw
holes in your outlet box project using variations of the legacy envelope method.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ
NOTE Verify that Application  MoldWizard is active.

NOTE Illustrations vary slightly from your assembly because of


the model and parting changes you made.

Step 1 Open your mdp_outlet project.


 Filter to and open outlet/mdp_outlet_top.
If needed, a staged assembly for this activity is in:
... / moldwizd / outlet_4 /

Step 2 Define an envelope for a sub-insert at only one screw


location.
 Choose the Sub-Insert icon:

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-9
Sub Inserts

The Sub-Insert Design dialog appears.

 Choose Insert Envelop . . . À


The dialog updates to reflect the Envelope mode of working.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ
Á

 Choose Envelope . . Á

The active product sub assembly becomes the displayed part.


The work part is the core by default, or the cavity if you have
been working in that part.

The work layer changes to MW_InsertHeadLayer: 165 by default.


The layer for core or cavity geometry is displayed.
We want to create inserts in the cavity.

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Sub Inserts

 On the Sub-Insert Design dialog, set Working Part to


mdp_outlet_cavity . . . Â

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

The cavity layer becomes Selectable, and the core layer becomes
Invisible.
The cavity work piece should be visible. You will choose one
cylinder for a screw hole and create a cylindrical envelope.

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All Rights Reserved Student Manual 8-11
Sub Inserts

 Orient the view so the cylindrical face of one of the screw


core posts is visible and easy to select.

Make sure this face is easy to select.

ÏÏÏ
ÏÏÏ
Step 3 Create a cylindrical envelope.

ÏÏÏ
8
ÏÏÏ
 In the Envelope dialog:

Set Definition Method to Extremity Faces

Set Shape to Cylinder.

À
Á

The prompt reads Select extremity faces"

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Sub Inserts

 Select and confirm a cylindrical face as shown below:

ÏÏÏ
 Choose Apply.
ÏÏÏ
The following dialog appears: ÏÏÏ
8
ÏÏÏ

 Choose Circumscribed: you need a cylinder that surrounds


the face you selected. Inscribed creates a cylinder that is
contained inside the volume of face(s) you select.

A cylindrical envelope is created and highlighted for editing.

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All Rights Reserved Student Manual 8-13
Sub Inserts

 The Envelope dialog enters Edit mode. Edit the following


parameters:

Set D = 3/8

Set Z2 = 2.125

Select values here:

Edit Values Here:


Remember to use
the Enter key to
activate your

ÏÏÏ entry.

ÏÏÏ
ÏÏÏ
8
ÏÏÏ  Choose Apply.

The cylinder is long enough to extend beyond the planar back"


face of the work piece, making it easy to see and select, even if
shading is enabled.

 Choose Cancel to return to the Sub-Insert Design dialog.

Step 4 Complete the insert head by trimming the envelope to the


cavity parting sheet.

 In the Sub-Insert Design dialog choose Head.

The prompt reads Select target body." The default action is


Trim by Parting Surface.

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Sub Inserts

 Select and confirm the cylindrical envelope, as shown below:

Select this body

 Choose Select Tool Object from the Selection Step area:


ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

The parting sheet is pre-selected.

 Choose Apply.

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Sub Inserts

The part is trimmed. The following dialog appears:

 If the subinsert trim direct is correct, choose OK.

The insert head is trimmed to the same face as the cavity insert.

 Choose Cancel to return to the Sub-Insert Design dialog.

Step 5 Create a foot", or attachment body, for the insert.

 From the Sub-Insert Design dialog choose Foot.

ÏÏÏ Selection Step Attach Face (on Head) is preselected, and the
ÏÏÏ prompt reads Select Attach Faces."
ÏÏÏ
8
ÏÏÏ

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Sub Inserts

 Select and confirm the circular end face of the head on the
end that was NOT trimmed, as shown below.

 Choose Selection Step Mounting Face (on Cavity):

The prompt reads Select Mounting Face."

 Choose the planar face opposite from the cavity contours, as ÏÏÏ
shown below: ÏÏÏ
ÏÏÏ
8
ÏÏÏ
Select this planar face

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All Rights Reserved Student Manual 8-17
Sub Inserts

 Change the Shape to Cylinder.

ÏÏÏ  Choose OK.


ÏÏÏ
ÏÏÏ
8
ÏÏÏ
The parameter list changes from Box to Cylinder parameters.

 Choose Apply.

The sub-insert is created in the product sub-assembly.

The dialog changes to Edit mode.

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Sub Inserts

 Edit the diameter, as shown:

 If necessary, select the D expression in the list


 Key in the value 1 in the edit window
 Press Enter

ÏÏÏ
ÏÏÏ
 Choose OK to update the foot. ÏÏÏ
8
ÏÏÏ
Step 6 Examine the cavity component.

 Cancel from Sub-Insert Design.

 Use the Assembly Navigator or the Window pull down to


make mdp_outlet_cavity the displayed part.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-19
Sub Inserts

 Make layer 165 Selectable.

Only the trimmed head is found in the cavity part. The foot does
not exist in this part in any layer.

Step 7 Examine the sub-insert component.


 Use the Window  More Parts... pull down to make
mdp_outlet_cavity_si_1 the displayed part.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

 Make category ALL Selectable.

MoldWizard Design Process EDS MoldWizard V18.0.3


8-20 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Sub Inserts

In the sub-insert part, you will see the complete sub-insert as


an orange body. There is also a dashed yellow body, visible
primarily around the foot" where it is larger than the orange
body. The yellow body is used in conjunction with the Create
Pockets function. You had a brief preview of pockets earlier in
the class. Pocket cutting is practiced in the lesson on standard
parts.

Step 8 Prepare to create a sub-insert by profile split.

 Use the Window pull down to make mdp_outlet_cavity the


displayed part.

 Make the following layer settings:


8 . . . . . . . . Work
165 . . . . . . Selectable
Others . . . Invisible

We make 8 the work layer because it is MW_PartingCavityLayer,


the layer where MoldWizard places cavity geometry. ÏÏÏ
ÏÏÏ
We are going to create a custom" envelope using profile split
on the cavity body. ÏÏÏ
8
ÏÏÏ
Step 9 Create a separate body at the other screw location.

 From the MoldWizard toolbar choose the Tools icon.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-21
Sub Inserts

 Zoom your view on the area of the other" screw - the one
that does not have a sub-insert:

Edge loop for split

ÏÏÏ
ÏÏÏ  Choose Profile Split.

ÏÏÏ
8
ÏÏÏ
 Select the work piece body as the target solid.
 Select the edge shown above as the first edge, and use the
traverse loop function to accept the remaining segment of
the loop.
 Select OK, the Vector Constructor dialog opens.
 Fit the view.
 In the Vector Constructor, choose the +ZC Axis as the
sweep direction, then OK. Note: +ZC must be selected,
even if it is already selected by default.
 In the Extrude Distance dialog accept the default by
choosing OK.
It is true the sweep is longer than necessary, but it will not hurt
anything to accept it.
After a few seconds the volume of the insert within the extruded
sheet is split into a separate solid.
All parameters are retained. The system uses an extracted body
and opposite trim operations to perform the split."

MoldWizard Design Process EDS MoldWizard V18.0.3


8-22 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Sub Inserts

Step 10 Define a sub-insert, using the body created by Profile


Split as the head.

 Choose the Sub-Insert icon, and Inset Envelop.

 In the Sub-Insert Design dialog, choose Foot.

The display part becomes the mdp_outlet_prod sub assembly.


The cavity should remain the work part.

 If mdp_outlet_cavity did not remain as the work part, use the


Working Part pull down in the Sub-Insert Design dialog to
change it now.

Selection Step Attach Face is pre-selected, and the prompt


reads Select Attach Faces."

 Select the circular end face of the solid created by Profile


Split, as shown below.

 Choose Selection Step Mounting Face.


ÏÏÏ
ÏÏÏ
 Select the outer" face of the split body, opposite to the part
cavity, as shown below: ÏÏÏ
8
ÏÏÏ
Á Select this face as
the Mounting Face À Select this face as
the Attach Face

 Change the Shape to Cylinder.

 Choose APPLY to create the foot.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-23
Sub Inserts

 Set the parameters as shown below:

Type:
D ........... 1
Z_L . . . . . . . . . 0.5
D_clr . . . . . . . . 0.04
X1 . . . . . . . . . . 0
Y1 . . . . . . . . . . 0

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ
 Choose OK to update the foot.

 Cancel from the Foot and Sub-Insert Design dialogs.

 Use the Window pull down to make mdp_outlet_top the


displayed part.

MoldWizard Design Process EDS MoldWizard V18.0.3


8-24 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Sub Inserts

 Make Layers 165 and 175 Selectable.

ÏÏÏ
ÏÏÏ
Step 11 Save your work.
ÏÏÏ
8
ÏÏÏ
 From the Menu Bar choose File  Close  Save All and
Close.

This concludes Activity 8-1.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 8-25
Sub Inserts

SUMMARY Sub-inserts are needed frequently.


MoldWizard provides a robust standard parts
approach, which requires little or no
explanation, and a complex legacy system
which you practiced in this lesson.

In this lesson you:


 Created sub-inserts using variations of the
envelope method.

ÏÏÏ
ÏÏÏ
ÏÏÏ
8
ÏÏÏ

MoldWizard Design Process EDS MoldWizard V18.0.3


8-26 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Gates and Runners


Lesson 9

PURPOSE In this lesson you will use MoldWizard utilities to


complete Gating and Runner systems.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Place Gates in a mold project.


 Attach a Runner system to your gates.

This lesson contains the following activities:

ÏÏÏ
Activity Page
ÏÏÏ
9
9-1 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9-2 Runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-1
Gates and Runners

Gates and Runner Systems Overview


Plastic molds have flow pathways that direct the plastic to the mold cavities.
The design of these pathways vary depending on 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; Sprues, Runners
and Gates.

1. The Sprue is the path from the outside of the mold to the parting surface. A
standard Sprue Bushing usually forms this section.

2. The Runner is a channel that is cut into the parting surface of the cavity, core
of both that begins at the end of the Sprue and provides a pathway to the fill
location of the mold cavity.

3. The Gate is the final pathway from the runner to the cavity. Gates come in a
variety of designs depending on the molding characteristics and cosmetic
requirements of the molded product.

MoldWizard provides tool to design sprues, runners and gates.

CAVITY

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
PRODUCT

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÏÏÏ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÏÏÏ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
9
ÏÏÏ ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
GATE
SPRUE

ÎÎÎÎÎÎÎÎÎÎ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÎÎÎÎÎÎÎÎÎÎ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
RUNNER

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
CORE

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

MoldWizard Design Process EDS MoldWizard V18.0.3


9-2 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Gate

A gate is the part of the feed system that


connects a runner with the mold
impression. MoldWizard provides several
gate types in a predefined library. You
may customize the existing library, or
extend it with your own gate designs.

Balance - Balanced patterns are used


for multi cavity molds when the gates are
to be created in the same position in each
instance. When a balanced gate is
modified, repositioned, or deleted, all
corresponding gates will update
accordingly.

Position - Gates may be installed in the


cavity, core or both depending on the
gate type. For example, sub-gates or fan
gates almost always belong to just the
cavity or core, whereas a round gate may
be centered on the parting plane and cut
into both the cavity and core equally.

This setting determines whether the


orientation of the gate to be created will
be on the core or cavity side of the mold.

If the gate is cut into both the cavity and


ÏÏÏ
core at the parting plane, either option
ÏÏÏ
9
may be used.
ÏÏÏ
Method - There are two operation
modes: Add and Modify. When a gate is
selected, modification mode will be set.
The parameters related to the selected
gate will be displayed in the editing
window. If you change to the Add option,
you will be able to add a new gate
according to the type and other
parameters defined in the dialog.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-3
Gates and Runners

Bitmap - a schematic image of the selected gate type is used to show shape,
parameters, and origin location of the gate.

Expression List - The available expressions are listed in a central window. The
selected parameter is made available for edit in the Expression Edit window.

Name - the system provides a default name for gate components. You may
enter a name of your own choosing.

Reposition Gate provides Translation and a Rotation dialogs, similar in function


to the tools in Cavity Layout.

Delete Gate removes single unbalanced gates or all members of balanced gate
sets. If there are no other gates of the same name, the corresponding part file is
closed.

ÏÏÏ
ÏÏÏ
9 The Edit Register File and Edit Data Base functions work the same as Standard
ÏÏÏ Part, Mold Base, and other libraries.

Reference allows you to change the parent part for Balanced gate components.
Gate components are added to the part designated by Reference. Solid bodies
are WAVE linked into the FILL part. The default parent for gate components
is the product or PROD subassembly.

MW_GateReferenceDisplay in the default file controls if the Reference pull down


appears in the dialog. If set to 1 the list appears. If set to 0 the list does not
appear and components will always be added to PROD.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-4 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Gate Point Indication

The gate point sub-function enables you to indicate the gate origin point.

When you choose Gate Point Indication, the Gate Point dialog will appear:

Point Subfunction allows you to create a point using the familiar UG point
interface.

Face/Curve Intersection creates the intersection point between a face and a


selected curve or edge.

Plane/Curve Intersection creates the intersection point between a plane and a


selected curve or edge.
ÏÏÏ
ÏÏÏ
9
TIP Do not edit Gate Design Parameters until a Gate Point has been
ÏÏÏ
specified.

The action of defining a Gate Point Location will cause all parameters
to reset to their default values.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-5
Gates and Runners

Point on Curve works the same way as points for variable radius and variable
taper. You first select an edge or curve. A "work point" will be created on the
end of curve.

You can move the highlighted point along the curve by following methods:
 drag the % scroll bar
 drag the value scroll bar
 numeric input %
 real value input

Point on Face - A point is created on a face by this function. A work point will
be created on the center of the face. The point is adjusted by sliders or numeric
input, either in XYZ or along a specified vector direction.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

Delete Gate Point - Deletes a selected Gate Point.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-6 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Activity 9-1: Gates

In this activity you will add gate components to the two cavity tray mold.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open the tray mold assembly.

 Open mdp_tray_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / tray_4 /

 Set the view to TFR-TRI.

Step 2 Define Initial Gate Parameters.

 Choose the Gate icon.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ
NOTE Do not choose OK or Apply in the following steps until
instructed to do so!

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-7
Gates and Runners

The Gate Design dialog opens.

 Set Balance to Yes . . . . . À

 Set Position to Cavity . . . Á

 Set Type to submarine . . Â

ÏÏÏ
ÏÏÏ
9  Set Reference to mdp_tray_prod . . Ã
ÏÏÏ
Ã

MoldWizard Design Process EDS MoldWizard V18.0.3


9-8 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Step 3 Define the Gate Point Location.

 Choose Gate Point Indication . . . À

À
The Gate Point dialog opens.

 Choose Point on Face . . . . Á

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-9
Gates and Runners

The Face Selection dialog opens.

 Select the back, outer face of the product model . . . . Â

The Point Move on Face dialog opens.

Ã
Ä
ÏÏÏ
ÏÏÏ
9 Å
ÏÏÏ Æ
 Accept the default X value . . . . Ã

 Verify Y = 0.000 . . . Ä

 Set Z = 8.000 and press Enter . . Å

 Choose OK . . Æ

MoldWizard Design Process EDS MoldWizard V18.0.3


9-10 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

The Gate Point dialog reappears.

Ç
 Choose Back to return to the Gate Design dialog Ç

Step 4 Define the remaining Gate Parameters and apply the


Gate Design.

 Verify and set Gate Parameters as necessary:

d ........... 1
A ........... 15
B ........... 40
HD . . . . . . . . . . 12
OFFSET . . . . . 1

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

 Choose Apply.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-11
Gates and Runners

The Point Constructor dialog opens.


The prompt reads Pick a point - Specify inferred point."
 Choose Existing Point in the Point Constructor dialog.

 Select the existing point on the back outer face that was
created in the previous step.
A vector arrow appears on the coordinate system at the base of
the sprue. The Vector Constructor dialog opens.
The correct gate orientation is in the direction of material flow
into the mold. For this mold assembly, it is along XC+ or XC-.
 Set the applicable XC vector icon in the Vector Constructor,
and then choose OK.
The system creates gates for both cavities.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

NOTE If two gates do not appear as illustrated, consult with the


instructor to determine the reason(s).

MoldWizard Design Process EDS MoldWizard V18.0.3


9-12 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

 Cancel the Gate Design dialog.


 Choose File  Save All. Do not close the part file.
This concludes Activity 9-1.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-13
Gates and Runners

Runner

The runners are filling paths from the


sprue to the gates. Runners are designed
by defining a path that the runner will
follow and 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 MoldWizard Runner module provides


tools for creation and editing of 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 will be subtracted from the core and
cavity after the design is confirmed.

MoldWizard has five predefined types of


cross section: circular, trapezoidal,
parabolic, hexagonal and semi-circular.

By default, all the geometry is created in


the FILL component. MoldWizard
recognizes the default part for the

ÏÏÏ placement of gating and runners by the

ÏÏÏ
9
presence of the part attribute UM_GR".

ÏÏÏ
Runner Design Steps

 Define guide string(s)

 Projection onto parting faces

 Create runner channels

MoldWizard Design Process EDS MoldWizard V18.0.3


9-14 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Define Guide String

There are three methods to define a guide string. The method you choose will
depend on the complexity of the runner channel, parting surface and
requirements for parametric adjustment. The first one is importing a sketch
pattern, the second is creating curves in pre-defined shape, and the third is to
select existing curves.

Sketch Pattern

The import Sketch Pattern method uses six


predefined parametric sketch patterns to
define adjustable runner guide patterns.
Sketch patterns may be selected from the
Available Patterns pull down menu and
imported to the runner component by
pressing OK or Apply.

User defined runner patterns may be


added to the option menu by creating a
sketch model, a supporting spreadsheet,
bitmap image and adding their paths to the
sketch pattern register file. (This general
ÏÏÏ
procedure is used in several modules, and
ÏÏÏ
9
is explained in detail in the on line
documentation). ÏÏÏ
Available sketch patterns include 2, 4, 8, and 16 cavity patterns, a circular
pattern, and an s-shaped pattern.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-15
Gates and Runners

Curves through Points

The dialog offers four pre-defined shapes, each located by two


points.

Guide String Shape is a pull down list offering the four shapes shown
at the right.

Choosing Point Subfunction will initiate prompts to select the two


points.

When existing curves are selected and highlighted, Incremental


Length, Reposition, and Delete are available to make edits.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ
Add / Remove Curves from Strings

When the Add / Remove Curves from Strings option is active, you may use MB1
select to add existing curves to a guide string, and Shift+MB1 deselect to
remove curves from a guide string.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-16 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Projection onto parting faces

If the parting surface is non-planar, the linear patterns provided would lie
inside the core or cavity tool steel at various places. You will want to project
runner patterns on to the parting so that channels lie on the parting.

Curves

Select guide curves to project to the parting.

ÏÏÏ
ÏÏÏ
9
Parting Faces
ÏÏÏ
Select faces on which to project the curves.

Copy Method
Move creates projected curves. The originals are deleted.
Copy leaves the original curves and creates projected curves that are not
associated.
Associate creates projected curves that are associative to the original curves and
to the selected parting faces.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-17
Gates and Runners

Create Runner Channel

MoldWizard will automatically find all the


guide strings in the work part and create 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, the
system will retrieve the selected channel
data and present it for modification.

There are five Cross Section shapes


available; circular, parabolic, trapezoidal,
hexagonal and semi-circular; as shown
below:

ÏÏÏ
ÏÏÏ
9
ÏÏÏ
Other Runner Design Options

Reposition and Delete

With these buttons you can move or delete a selected runner channel.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-18 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Activity 9-2: Runners

In this activity you will add a runner component, and create the runner and gate
pockets in the two cavity tray mold.

Step 1 Open the tray mold assembly in the top view.

 If necessary, open mdp_tray_top.

If needed, a staged assembly for this activity is in:


... / moldwizd / tray_5 /

 Orient the display to Top.

Step 2 Define the runner guide string.

 Choose the Runner icon.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-19
Gates and Runners

The Runner Design dialog opens.


Define Guide String is the default selection step . . . . À
Sketch Pattern is the default Definition Method . . . . Á

ÏÏÏ
ÏÏÏ
9
 Set Available Patterns to 2 Cavities . . . Â

ÏÏÏ  Set guide string length A to 32 . . Ã


Hint: Do not forget to press Enter.

 Choose Apply.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-20 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

A guide string 32mm long appears . . . . . Ä


between the two submarine gates . . . . . Å

Å Ä

NOTE This mold design has a planar parting surface; projection


of the guide string onto the parting sheet is not required.

Step 3 Create the runner channel.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ
À

 Choose the selection step Create Runner Channel . . À

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-21
Gates and Runners

The lower portion of the Runner Design dialog changes.

Ä
 Set or verify the following parameters:

Cross Section . . . . . . . Circular . . . . . . Á


A .................. 5.5 . . . . . . . . . . Â
Runner Location . . . . . Core . . . . . . . . . Ã

ÏÏÏ Cold Slug Position . . . Both End . . . . . Ä

ÏÏÏ
9
ÏÏÏ TIP Circular runners are symmetric in the Core and Cavity.
Either location is appropriate for circular runners.

 Choose OK to create the Runner profile.

 Cancel the Runner Design dialog after the part updates.

MoldWizard Design Process EDS MoldWizard V18.0.3


9-22 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

The illustration shows the 5.5mm diameter runner extending along the core
and cavity boundary between the two submarine gates . . . Å

Step 4 Create the gate and runner pockets.

 Choose Create Pockets.

The Create Pockets dialog displays.

 Choose Target + Standard.


ÏÏÏ
ÏÏÏ
9
ÏÏÏ

The cue line reads Select Target Bodies, then Standard Parts.

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-23
Gates and Runners

The core and cavity bodies are the target bodies that will receive
pockets defined by the gates and the runner segment.

 In the graphics window, select the core and cavity bodies.


Hint: UM_CORE_BLOCK and UM_CAVITY_BLOCK.

 Choose OK in the Create Pockets dialog.

The cue reads Select Standard Parts."


The gate and runner components of the fill part define pocket
geometry.

NOTE Selecting any one of the fill components will select them
all.

 In the graphics window, select either gate or the runner.

 Choose OK on the Standard Parts dialog box.

MoldWizard creates the runner and gate pockets in the cavity


and core.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

MoldWizard Design Process EDS MoldWizard V18.0.3


9-24 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

Step 5 Examine the Core Body.

 Choose Window  More Parts and open mdp_tray_core.

Step 6 Examine the Cavity Body.

 Choose Window  More Parts and open mdp_tray_cavity.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-25
Gates and Runners

Step 7 Restore the display to mdp_tray_top.


 Select Window  mdp_tray_top

 Use the Assembly Navigator to make mdp_tray_top the


Work Part.

 Dismiss the Assembly Navigator window.

 Set the view to TFR-TRI, wireframe, hidden lines visible.


 Choose File  Save All. Do not close the part file.

This concludes Activity 9-2.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

MoldWizard Design Process EDS MoldWizard V18.0.3


9-26 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Gates and Runners

SUMMARY MoldWizard provides customizable libraries of


gates and runners, and the Electrode utility, to
complete your mold tooling design.

In this lesson you:


 Placed Gates for your tray.
 Added a simple runner system to your tray
project.
 Created pockets for all fill components.

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

EDS MoldWizard Design Process


All Rights Reserved Student Manual 9-27
Gates and Runners

(This Page Intentionally Left Blank)

ÏÏÏ
ÏÏÏ
9
ÏÏÏ

MoldWizard Design Process EDS MoldWizard V18.0.3


9-28 Student Manual All Rights Reserved Unigraphics V18.0.3.2
Cooling Channels

Cooling Channels
Lesson 10

PURPOSE The current approach to cooling uses a Standard


Parts approach to specify both drilled channels and a
variety of plumbing components. A previously used
approach was focused on schematic circuit design.
You may encounter the older method if your company
has legacy mold data.

OBJECTIVES Upon completion of this lesson, you will be able to:

 Add Standard Cooling Parts to a tooling assembly.


 Add Cooling Lines to a tooling assembly.

This lesson contains the following lessons.

Activity Page
10-1 Cooling Using Standard Parts . . . . . . . . . . . . . . . . . 10-5
10-2 Schematic Cooling Circuit Design . . . . . . . . . . . . . 10-26

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EDS MoldWizard Design Process
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Cooling Channels

Cooling

When you choose the Cooling icon a Cooling Method dialog appears.

À
Á

Choose Channel Design À to activate the legacy cooling subsystem described


later in this lesson.

Choose Standard Part Á to activate the current (preferred) subsystem.

Set the MW_CoolUserInterface value in the mold_defaults file to enable the


desired system(s).

MW_CoolUserInterface = 0, use guide line method.

MW_CoolUserInterface = 1, use standard part method.

MW_CoolUserInterface = 2, display dialog to select guide line or standard part


method.

By default, and in the classroom, MW_CoolUserInterface = 2.

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Cooling Component Design

When you choose Standard Part on the Cooling Method dialog, the following
dialog will appear:

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Cooling Channels

The cooling hole standard part supports a variety of component types, such as
pipe-plug, baffle, connector-plug and extension plug. Component
configuration may be changed after the hole is installed.

The Standard Parts cooling method has two main steps:

 add a standard part that forms the hole


 add a component to a selected hole

Hole Procedure

 Choose a Parent:
 For holes in the mold base choose *_cool."
 For holes in inserts choose *_prod."

 Choose the component type from the COMPONENT_TYPE option


menu.
 Choose a thread size.
 Choose Apply.
 Select a placement plane and proceed with PLANE object placement.
 Edit the cooling hole position and dimensions using the Operation and
Dimension pages.

Component Procedure

 With the hole selected and highlighted, choose a component type from
the listing window of the Cooling Component Design dialog.
 Set the size.
 Choose Apply.

The component will then be added as a child of the previously selected cooling
hole component. To change the component type:

Remove the previously installed component.


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 Edit the COMPONENT_TYPE of the cooling hole.
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 Choose and install a replacement component.

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Cooling Channels

Activity 10-1: Cooling Using Standard Parts

In this activity you will use the Standard Part approach to Cooling Component
Design.

The design requires that some of the cooling channels be placed at an


angle.

Do not worry about the mechanical interface between the cavity insert
and mold plates, or choosing the proper parent for components you
will add.

This design approach was simplified to help you to familiarize yourself


with the Cooling Component Design dialog and the positioning options
available for the Cooling Hole standard part.

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Cooling Channels

NOTE Verify that Application  MoldWizard is active.

Step 1 Open assembly desk_org_top from ... / moldwizd / cooling.

Step 2 Initiate Cooling Component Design.

 From the MoldWizard menu bar select the Cooling icon.

 ChooseStandard Part . . . . À

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Step 3 Create Cooling line # 1.

 From the Cooling Component Design dialog, if necessary,


choose the Catalog tab À, and the Cooling Hole option Á.

 Set the slider for Hole_1_Depth to 4.000 . . . Â

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 Choose the Dimension tab . . . Ã

 Set the value for C_CBORE_DEPTH to 0.375 . . . Ä


Hint: Do not forget to press Enter.

 Choose OK.

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Cooling Channels

 From the graphics screen select and confirm the Front Face
of the cavity insert as shown:

The view is oriented to the plane of the face you selected.


The point constructor displays.
The cue reads:
Pick up a point to add standard part: - ..."
The last part of the cue varies, depending upon how or if the
Point Constructor was last used in your session.

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Cooling Channels

 In the Point Constructor dialog choose Cursor Location.

The cue now reads:


Pick up a point to add standard part: - Indicate location of
point with the cursor."

 Indicate a point on the graphics screen at approximately the


cursor location shown:

The specified hole part is added, and a Position dialog appears.

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 From the Position dialog, in the Reference Point area, choose


Face Center . . . Å

Temporary dimension lines appear on the screen.

 Choose Drag . . . Æ

Æ
Temporary coordinates display at the cursor location. These
coordinates snap to rounded values determined by the settings
X Increment, Y increment, and Drag Decimal Place.

 Move your cursor to the position where:

X = 2.8
Y = 1.6

 Indicate that location by clicking.


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TIP You may also manually edit the X and Y values on the
Position dialog as Offset D1 and D2.

 Choose Cancel to dismiss the Position dialog.

The Cooling Method dialog appears.

Step 4 Create Cooling line # 2.

 Repeat the previous procedure, using the following


parameters:

HOLE_1_DEPTH . . . . 6.000
C_BORE_DEPTH . . . . 0.0
ANGLE_X . . . . . . . . . . -45
Hint: You may achieve greater angle variation than the slider
can achieve by editing Angle_X on the Dimension tab.
Face as illustrated.

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 Indicate in the approximate position shown:

 Choose the Face Center.

 Edit into position:

D1 = 1.2
Hint: Press Enter after each change.
D2 = 1.6

Step 5 Create Cooling Line # 3.

 Repeat the preceding procedure, using the following


parameters:

HOLE_1_DEPTH . . . . 6.000
C_BORE_DEPTH . . . . 0.0
ANGLE_X . . . . . . . . . . 45
NOTE We use Plus 45° on this side!

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Select the face illustrated:

From Face Center:


D1 . . . . . . . 1.2
D2 . . . . . . . 1.6

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Step 6 Create Cooling Line # 4.


Cooling Line # 4 is similar to cooling line # 1, except that it
does not have a counter bore.
HOLE_1_DEPTH . . . . 4.000
C_BORE_DEPTH . . . . 0.0
ANGLE_X . . . . . . . . . . 0.0
 Indicate a point the same distance from the face center as
the first hole, except the opposite side:

 From Face Center:


X . . . -2.8 or D1 . . 2.8
Y . . . -1.6 or D2 . . 1.6

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Step 7 Create Cooling Line # 5.


HOLE_1_DEPTH . . . . 6.250
C_BORE_DEPTH . . . . 0.0
ANGLE_X . . . . . . . . . . 0.0
From Face Center:
D1 . . 2.2
D2 . . 1.6

Step 8 Create the final cooling line # 6.


HOLE_1_DEPTH . . . . 1.500
C_BORE_DEPTH . . . . 0.375
ANGLE_X . . . . . . . . . . 0.0
From Face Center:
D1 . . 2.0
D2 . . 1.6

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hole is illustrated on the following page.

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Cooling Channels

3
2

4
5 6 1

Your cooling lines should look similar to the figure shown above.
Remember that you can always select a given cooling line and
modify its dimensions and position.
If you have difficulty, ask your instructor for assistance.

Step 9 Add Connector Plugs to cooling lines 1 and 6.

 If necessary, once again choose Cooling  Standard Part.

 Select cooling line #1.

 From the Cooling Component Design dialog choose the


Catalog Tab.

 Choose CONNECTOR PLUG and then choose Apply.

 Choose O-RING and then choose Apply.

Select Cooling Line # 6 from the graphics window and


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repeat the above steps.
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Step 10 Add Pipe Plugs to the remaining cooling lines.

 If necessary, choose Cooling  Standard Part.

 From the graphics window select Cooling Line #2.

 Choose PIPE PLUG from the Catalog Tab and Apply.

 Select Cooling Line # 3.

 Choose PIPE PLUG and then Apply.

 Repeat for Cooling Line #'s 4 & 5.

Step 11 Create pockets for the cooling lines and components.

 From the MoldWizard main menu bar select the Create


Pockets icon.

 Using the Target + Standard option select the cavity insert


from the graphics window then choose OK. Now choose
Select All then choose OK.

Step 12 Preview the BOM function.

 Choose the Bill of Material icon.

 Choose Standard Parts Only and BOM Record Edit.

The cooling components you added are shown in a large window


on the BOM Record Edit dialog. You will learn about Bill of
Material functions in an upcoming lesson.

Step 13 Save your work.

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 Choose File  Close  Save All and Close.
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This concludes Activity 10-1.

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Cooling Channels

Cooling Channel Design

Cooling Channel Design is a legacy tool that


allows you to interactively create cooling
channels in a mold assembly. If you use
Define Guide Path tools to construct guide
curves, there is associativity between
channels and their inlet face, and parametric
positioning of each complete circuit. You can
also create channels from curves created in
Unigraphics.

Channel Design Steps

There are two design steps in the dialog:

 Define Guide Path


 Generate Cooling Channel

Balanced and Non-Balanced

The radio buttons allow you to choose


between a balanced design and an
non-balanced design. The difference is in
the work part in which the channels are
created.

A balanced design is created in the PROD


part, and appears in all inserts.

A non-balanced design is created in the


COOL part. Channels in the COOL part are

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Cooling Channels

The Assembly Navigator illustration below shows the Work Parts for both
Balanced and Non-Balanced cooling channel creation.

Work Part is COOL for


Non–Balanced construction.

Work Part is PROD for


Balanced construction.

TIP
Before creating cooling channels, define your layout and add the mold
base.
Create the channels in a completed layout.

Define Guide Path

There are two methods to create a cooling guide


path:
 Use the sketching tool provided by the module.
 Create the guide path using standard Unigraphics modeling, and
import it into the cooling module.
If you create curves in native Unigraphics you must choose your work part

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according to the Cooling type you intend to use, Balanced or Non-Balanced.
The Balanced method uses the PROD part as the work part; therefore, for a
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Non-Balanced system, create curves in the COOL part.

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Create

The Create button activates Sketching" with the Cooling Module. This is a
tool which permits you to construct a series of associated smart" lines which,
together, make up a complete cooling path.

Lines are associative to the face on which they are placed. The first line is the
master for positioning; it may be positioned. Each successive line is a child" of
the one before it. If a parent is moved, all children move with it.

Create Procedure

 Select an inlet face, from which the first channel is drilled.


 Adjust the length if desired
 Select a second face, from which the second channel is drilled.
 A second guide path will automatically be created at an angle normal
to the second face to join up with the first guide curve.
 Adjust the position of the second guide line by the slider or the input
window - the line will glide along the first line.
 Continue to add curves in the same manner as the second curve until
the circuit is complete.
 At any time after the first line is defined, choose Create/Edit Guide
Path Position to create positioning constraints. The first line, at the
inlet face, is the point constrained.
 Click OK to complete the operation.

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Length

All cooling guide lines start with a default length. The first cooling line has a
default length equal to the full width of the mold plate or workpiece body
selected. Subsequent lengths depend on the distance between the selected face
and the previous cooling line. The length slider is used to adjust a line length.

NOTE The system constrains the length of child curves to be at


least the distance from the selected face to the parent
guide curve, to assure that a connection is maintained.

Position

A slider control and a text input box are provided to adjust the position of any
child guide line along its parent.

NOTE The Position input box and the position slider are grayed
out as the first line is created. Its position is controlled by
constraints, using Create/Edit Guide Path Position.

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Delete Guide Path

Delete a complete guide path by


selecting any member line.

Delete Guide Line

Delete a selected guide curve. Any child


curves will also be deleted.

Create/Edit Guide Path Position

Create/Edit Guide Path Position


initializes positioning for the first line
of the path. Since there is associativity
from the first line to each child, the
entire guide path is moved as the first
line is positioned. Subsequent lines can
be repositioned, each relative its
immediate parent, using the position
slider or text input box.

Add/Remove UG's Curve

This button allows you to import" guide curves created by normal UG


methods.

NOTE The curves must be created in the appropriate work part.

 Move cursor over to the graphic area and select the native UG curve.

Show Cooling Channel Relationship

Numbers appear on the screen to indicate parent child relationships in the


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Cooling Channels

Generate Cooling Channels

Diameter

Enter the desired channel diameter in


the text input window, or choose from
common pipe sizes.

Hole Type

Threaded Hole gives a channel


diameter equal to the tap drill size for
the selected diameter. Clearance
Diameter for the pipe size specified is
the second choice.

Start Type

Use a pull down list to


choose between:

 Flat ended
 Counterbored

End Type

 Flat ended
 Counterbored
 Blind end

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 Blind with a
specified extension
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channel.

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Cooling Channels

Delete Cooling Channel

Deletes a selected channel body.

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Activity 10-2: Schematic Cooling Circuit Design

In this activity you will create a cooling circuit pattern defined by a drawing on
the following page.

NOTE Verify that Application  MoldWizard is active.

Step 1 Open mdp_cup1_top from ... / moldwizd / cup1_4 /


To run channels through mold plates, we would need to import
the mold base before proceeding.
We will skip importing a mold base simply to make your screen
easier to interpret.
The circuit you will create is simplified to permit you to quickly
experience the use of Cooling Circuit Design.

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The layout of cooling lines is shown below. Guide lines are


shown in bold. The line marked À is the Master line. Parent
relationships are indicated by the symbols Á, Â and so on.

The face with the counterbored openings should be on the


exterior of the layout, to permit connections.
There are several valid choices of placement faces for the
layout. The faces illustrated were chosen to minimize the
number of faces containing drill start points, only two. This
optimizes the number of machining setups required.
Reference edges and values of Z dimensions are provided later.

5.500

Ä
1.500

À
5.500
Á

0.625 TYP.
(4) LINES

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Step 2 Create a master line to begin a balanced cooling circuit in


the inserts.

 Choose the Cooling icon.

 Choose Channel Design.

NOTE One of the four part instances displayed becomes the


work part. We expect it to be the one shown . . . À

 Identify which faces correspond to an exterior" position on


the layout relative to the WCS. You will select an exterior
face, for example the face shown as Á, when you roughly
place the Master line.

The hierarchy of guide lines is straightforward in this part.


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When editing other parts, particularly if you were not the
original designer, this feature is very useful to reveal the parent
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Cooling Channels

 Place your cursor over the face previously identified as an


exterior face, in the relative position approximately half the
cavity insert height, and one third of the total distance from
left to right.

 Select the face, indicating by a cursor location approximately


half the insert height, and approximately one third the
distance from the outside of the layout.

TIP If necessary, you can delete a guide line or an entire


guide path. When you delete a line, all child lines will
also be deleted.
Use Show Channel Relationships to reveal the parent
child relationship of lines.
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 Adjust the length to 0.625, then press Enter . . . . À

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As you select faces, remember that (1) you want fittings only on
exterior faces, and (2) you want to drill into only two faces.

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Cooling Channels

If necessary, refer to the illustration on page 10-27 for


positions and dimensions.
Guide lines are created in MW_CoolingPathLayer, 181 by default.
The cooling line À should remain highlighted. Size and position
should appear approximately as shown below:

NOTE From this page onwards, other occurrences of the product


are omitted for visual clarity.

Step 3 Create guide line two.


 Select the next face Á, with relative orientation to the first as
shown.

 Adjust Length to the minimum value the system will allow.


The minimum length available depends on where you placed the ÏÏÏ
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Cooling Channels

 Adjust the Position to 0.625

TIP Remember to press Enter after editing values on the


dialog.

NOTE The system might occasionally truncate a value, for


example, 0.625 to 0.624999... Do not be concerned about
such small discrepancies.

Step 4 Create guide line three.

 Place the third line on the same face as the first.

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 Adjust the line to these values:

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Length . . . . . . 4.875
Position . . . . . . 0.625

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Step 5 Create guide lines four and five.

 Place the fourth line on the same face as the second.

Type:
Length . . . . . . 4.875
Position . . . . . . 4.875

à Â

 Place the fifth guide line on the same face as one and three.

Type:
Length . . . . . . 4.875
Position . . . . . . 4.875

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Step 6 Create a positioning constraint for the circuit.

 Choose Create/Edit Guide Path Position.

The Create/Edit Guide Path Position dialog appears.

 Create position constraints by selecting both lines as shown,


and then enter values D1 and D2 in the dialog:

D2 = 2.50

D1 = 1.50

D1, D2

 Activate the toggle for Show Channel Relationship.

 If necessary, edit the position of any guide lines that are out
of place.

To Edit a cooling guide line:


 Select the line you want to edit.
 Use sliders or enter new values in the appropriate
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window.

10 Enter values whenever the exact dimensions are known.


ÏÏÏ
ÏÏÏ  Choose File  Save All.

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Cooling Channels

Step 7 Generate the cooling line solid bodies.

 Choose Generate
Cooling Channel . . À

The Cooling dialog


changes to Generate mode. À

Á
 Change End Type to
Blind End with
Extension . . Á

 Choose Apply . . Â
Â
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Cooling lines are generated, and remain highlighted for editing.
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Cooling Channels

Step 8 Modify parameters of specific cooling lines.

 Change the Display Mode to Partially Shaded.

Like standard parts, gating, and runners, cooling lines are


partially shaded.
Since all lines are highlighted, it is easy to change all of the
extension values with one edit.
Type:
Extension . . . . . . . . . . . 0.18 (Enter)

 Choose Apply.

 Shift-deselect all lines except the