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Chapter 6 Mold Volumes from Parting


Surfaces
Objective This chapter introduces:

9 Mold Volumes
9 Creating a Mold Volume from Parting Surfaces

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9 Classifying Mold Volumes

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9 Modifying Mold Volumes

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9 Splitting Failures

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The components that make up a mold are generated by creating mold
volumes that are then extracted to form the components. This chapter

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teaches how to create the mold volumes. How to create the extracted

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feature will be discussed later in the course.

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Mold volumes are surface features and do not contain solid geometry.
Mold volumes can include the core, cavity, sliders, lifters, inserts or
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any other component that are required to complete the mold. An
example of a mold volume is shown in Figure 6–1.
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Figure 6–1

Mold volumes can be either created by splitting the workpiece using


parting surfaces or using existing mold volume. In addition, you can
also create a volume directly without a parting surface. This direct
method will be discussed in the next chapter.

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The following must exist in the model to create a mold volume using a
parting surface:

• Parting surface
• Workpiece
• Reference part

By default, Pro/ENGINEER creates two volumes; however, you can


split the workpiece into one or two volumes if necessary. Figure 6–2
shows a one-volume split.

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One volume

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Figure 6–2

Figure 6–3 shows a two-volume split.


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Reference
model
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Volumes
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Figure 6–3

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6.1 How to Split the Mold


When you use a parting surface to split a mold, the system begins by
removing the volumes of the reference part, or any gates, runners, or
sprue from the workpiece. It then computes the volume of the
workpiece on each side of the surface and converts it into a volume.
This creates a "vacuum" in the workpiece, which is filled with plastic
during the molding operation.

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To create mold volumes using a parting surface, complete the

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following steps:

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1. Create the parting surface in the model. It must exist in the
model prior to splitting the mold volumes.

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You can use the MOLD 2. Click Mold Volume in the MOLD menu. The Split option is only

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VOUME menu to blank available if the Reference Model and Workpiece are not blanked

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and shade volumes that from the display.

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are created in the mold.
Shading helps identify the 3. Click Split in the MOLD VOLUME menu. The SPLIT VOLUME
completed volume and menu appears as shown in Figure 6–4.
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blanking can be used to
remove the volume from
the display for clarity.
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Figure 6–4
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The SPLIT VOLUME menu options are described in Table 6–1.


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Table 6–1
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Option Description
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Two Volume Splits the workpiece into two volumes.


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One Volume Splits the workpiece into only one volume.


All Wrkpcs Splits the workpieces. The geometry of all workpieces are
joined together and all reference parts are subtracted.
Mold Splits an existing volume.
Volume
Sel Comp Splits any part in the assembly.

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4. Click Done in the SPLIT VOLUME menu. The Split dialog box
appears as shown in Figure 6–5.

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Figure 6–5

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5. Select the parting surface when prompted and select the
button.

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6. In some cases, the parting surface divides the mold into more

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than two volumes. If so, you will be presented with an ISLAND
LIST menu similar to that shown in Figure 6–6. All of the islands
are listed and must be assigned to either of the mold volumes
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being created. Selected islands are assigned to the first volume
and the remaining islands are included in the second volume.
This is called classifying the mold volumes.
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As you drag your cursor


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over the island options, the


volume assigned to that
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island highlights.
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Figure 6–6
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7. Select the button in the Split dialog box.


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8. The first new volume is highlighted and you are prompted to


enter name for the first volume. Enter a name and select the
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button to create the volume. When prompted for the


name of the second volume, enter a name and select the
button to create the second volume. A Refpart Cutout and two
Split features are added to the model tree.

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6.2 Modifying Mold Volumes

To modify a mold volume, click Mold Volume > Modify and select the
volume to modify from the Selection Tools dialog box. The MOLD VOL
menu appears as shown in Figure 6–7.

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-2 A Figure 6–7
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The MOLD VOL menu options are described in Table 6–2.

Table 6–2
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Option Description
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Gather Creates a volume by selecting the mold assembly


surfaces.
Sketch Creates a volume by sketching.
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RefPart Cutout Creates a reference part cutout in a selected volume.


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Option Description

Trim to Geom Trims the selected volume to a part, quilt, or plane.


The volume shown in Figure 6–8 is trimmed to datum
plane MOLD_FRONT.

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Figure 6–8

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Round Creates rounds on selected mold volumes.
Offset Offsets the surfaces of a selected volume. You can
offset surfaces horizontally or tangentially.
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Draft Drafts selected surfaces.
Draft Offset Creates an area offset with drafted surfaces. The
example in Figure 6–9 shows an offset area with 15°
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draft.
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Offset area with draft


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Figure 6–9
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Option Description

Area Offset Offsets an area of a surface as shown in Figure 6–10.

Offset area of a surface

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Figure 6–10

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Replace Replaces a volume surface up to a datum plane or
Surface quilt surface using the REPLACE SURFACE dialog

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box, as shown in Figure 6–11.

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Figure 6–11
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6.3 Splitting Failures

The most common causes of split failure include the following:

• Gaps between the reference part and workpiece are not closed off
by a single parting quilt.
• Mold components have different absolute accuracies.

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• A hole in reference part is not closed off by the parting surface.
• The parting surface and volume do not intersect.

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• Irregular geometry in the intersecting curves.

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• Geometry checks in the model.

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If a split fails to be created, select the Geom Option element in the
Split dialog box and select the button. The GEOM OPTION

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menu appears as shown in Figure 6–12.

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Figure 6–12
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Be default, the Make Select the Make Curves option and click Done/Return. This option
Volume option is used enables you to create intersection datum curves to investigate the
when creating a split. causes of the failure.
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Exercise 6a Football Stand


In this exercise, you will modify the workpiece part. You will create
volumes using the split feature, modify the parting surface, and shade
the volumes.

Goal After you complete this exercise, you will able to:

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9 Redefine Workpiece
9 Create Volumes

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9 Shade Volumes

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Task 1: Open foot_mold manufacturing file.

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1. Change the working directory to ch6 and ensure that all files

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have been erased from memory.

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2. Open foot_mold.mfg. The model appears as shown in
Figure 6–13.
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Figure 6–13

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3. To display features in the model tree, select > Tree


Filters. Select Features from the Model Tree Items dialog box
and select the button. The model tree appears as shown
in Figure 6–14.

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Figure 6–14

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Task 2: Redefine the workpiece.

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Select the FOOT_MOLD_WRK.PRT in the model tree and click
Edit Definition from the right-mouse button pop-up menu. The
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Automatic Workpiece dialog box appears.

2. Enter [6] for the overall dimension of the workpiece in the X- and
Y-directions, enter [2.1] for the +Z Cavity, and enter [0.5] for the
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-Z Core.
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3. Select the button. The model appears as shown in


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Figure 6–15.
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Figure 6–15

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Task 3: Create volumes.

1. Click Mold Volume > Split or select the button. The SPLIT
VOLUME menu appears.

2. Accept the defaults and click Done. The Split dialog box appears
and you are prompted to select the parting surface.

3. Select the parting surface shown in Figure 6–16 and select the

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button.

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Parting
surface
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Figure 6–16
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Notice that the volumes are not created and the Troubleshooter dialog
box appears. The message for item 1 is:
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Split feature has failed. Volume cannot be split due to a hole in the
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parting surface. The hole is highlighted in green. Redefine parting


surface to patch the hole.
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4. Cancel the split operation and return to the MOLD menu.


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5. Redefine the parting surface to intersect the workpiece.

6. Select the button. The SPLIT VOLUME menu appears.

7. Accept the defaults and click Done. The Split dialog box appears
and you are prompted to select the parting surface.

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8. Select the parting surface shown in Figure 6–17 and select the
button. The ISLAND LIST menu appears as shown in
Figure 6–17. This enables you to assign the three separate
volumes in this model to either of the two split volumes.

Selected islands are


assigned to the first
volume and islands that
are not selected are

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included in the second
volume.

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Figure 6–17

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9. Drag your cursor over the island options to highlight each island.

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10. Select the Island1 option and click Done Sel.

11. Select the button in the Split dialog box. The Volume
Name dialog box appears as shown in Figure 6–18.
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Notice the button


in the Volume Name dialog
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box.
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Figure 6–18
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12. Enter [cavity] as the name and select the button.


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13. The Volume Name dialog box reappears to name the second
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volume. Enter [core] as the name and select the button.


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The volumes appear as Split id # and Split id # in the model tree. You
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can use the Name option in the ASSEM SETUP menu to assign new
names for the features, or you can rename them directly in the model
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tree.

14. Blank the reference part, workpiece, and parting surface.

15. Click Mold Volume > Shade. The Search Tool dialog box
appears as shown in Figure 6–19.

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Figure 6–19
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16. Move CAVITY to the items selected area and close the dialog
box. The cavity volume appears as shown in Figure 6–20.
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Figure 6–20

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17. Click Continue in the CntVolSel menu and select CORE using
the Search Tool dialog box. The core volume appears as shown
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in Figure 6–21.
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Figure 6–21

18. Click Done/Return in the MOLD VOLUME menu.

19. Unblank the reference part, workpiece, and parting surface.

20. Save the mold model and erase it from memory.

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Exercise 6b Scoop Model


In this exercise, you will modify the workpiece part. You will create
volumes using split feature, and shade the volumes.

Goal After you complete this exercise, you will able to:

9 Redefine workpiece

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9 Create Volumes

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9 Shade Volumes

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Task 1: Open scoop_mold manufacturing file.

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1. Open scoop_mold.mfg. The model appears as shown in

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Figure 6–22.

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Figure 6–22
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2. Display features in the model tree. The model tree appears as


shown in Figure 6–23.
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Figure 6–23

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Task 2: Create volumes.

1. Click Mold Volume > Split or select the button. The SPLIT
VOLUME menu appears.

2. Accept the defaults and click Done. The Split dialog box appears
and you are prompted to select the parting surface.

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3. Select the button and select the button. From the
list of quilts that are returned in the items found section, select

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MAIN_SURF, move it to the items selected area and close the
Search Tool dialog box.

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4. Select the button in the Select dialog box. The volumes
cannot be created and the Troubleshooter dialog box appears.

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5. Cancel the split operation and return to the MOLD menu. The

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message window reads, "Open geometry found in the results".

The Split feature has failed 6. Select the Quit button from the FEAT FAILED menu.
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due to problems in the
intersection of parting 7. Increase the workpiece dimension to [16] in Y-direction.
geometry with the mold
volume. Intersection
8. Select the button. The SPLIT VOLUME menu appears.
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curves are highlighted in


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green, ends of gaps in 9. Accept the defaults and click Done.


intersection curves are
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highlighted in red. 10. The Split dialog box appears and you are prompted to select the
parting surface.

11. Select MAIN_SURF and click Done Sel. The ISLAND LIST
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menu appears.
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Selected islands are 12. Drag your cursor over the island options to highlight each island.
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assigned to the first


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volume and islands that 13. Select the Island1 and Island3 options and click Done Sel.
are not selected are 14. Select the button in the Split dialog box. The Volume
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included in the second Name dialog box appears as shown in Figure 6–24.
volume.
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Figure 6–24

Notice the button 15. Enter [scoop_1] as the name and select the button.

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in the Volume Name dialog
16. The Volume Name dialog box reappears. Enter [scoop_2] as the

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box.
name and select the button.

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The volumes appear as Split id # and Split id # in the model tree. You

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can use the Name option in the ASSEM SETUP menu to assign new
names for the features.

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17. Select the button. The SPLIT VOLUME menu appears.

18. Click One Volume > Mold Volume > Done. The Split dialog box
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and Search Tool dialog box appear.

19. Select SCOOP_1in the Search Tool dialog box. You are
prompted to select the parting surface.
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20. Select the button and select the button. Select


PART_SURF_1 in the Search Tool dialog box.
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21. Select the button. The ISLAND LIST menu appears.


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22. Drag your cursor over the island options to highlight each island.
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23. Select the Island1 option and click Done Sel.


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24. Select the button in the Split dialog box. The Volume
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Name dialog box appears.


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25. Enter [scoop_3] as the name and select the button.


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26. Shade each volume. They appear as shown in Figure 6–25.

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Figure 6–25

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27. Save the mold model and erase it from memory.

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Exercise 6c Outlet Strip Project


In this project, you will perform the following:

9 Perform a draft check on the outlet_strip part


9 Apply a shrinkage ratio to all dimensions of the part
9 Create the mold model, reference model, and parting

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surface
9 Split the mold into two volumes

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Task 1: Open outlet_strip.prt.

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1. Open the outlet_strip.prt. The part appears as shown in
Figure 6–26.

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Figure 6–26

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Task 2: Perform a draft check on the model.

1. Perform a Draft Check on the model by clicking Analysis >


Geometry > Draft. Select the top of the model and click Pick
from list from the right mouse button pop-up menu. Click
SolidGeom and select .

2. Activate the Direction field in the References area of the


Definition tab on the Draft dialog box and select datum plane

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TOP as the pull direction.

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3. Use the icons and angle value in the Draft Angle area to identify
the approximate draft angle of your model on different surfaces.

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4. Select the draft features in the model tree and click Edit from the

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right mouse button pop-up menu. Determine the exact draft
angles on drafted surfaces. Does this model have enough draft

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to be molded?

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5. Add a shrinkage ratio value of [0.002] to all dimensions of the
model using the Shrinkage option in the PART SETUP menu.
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Task 3: Create a manufacturing file.

1. Create a new manufacturing file to begin creating the mold for


this model. Name the file [OUTLET_MOLD].
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2. Mate the bottom surface of the outlet_strip model to the


MAIN_PARTING_PLN datum plane. Align FRONT with
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MOLD_FRONT and RIGHT with MOLD_RIGHT. The model


appears as shown in Figure 6–27.
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Figure 6–27

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By selecting the Same Task 4: Create a workpiece in the mold model.
Model option, you identify
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your reference model and 1. Create the reference model using the Same Model option.
design part as the same
model. Any changes made 2. If you receive an absolute accuracy conflict, resolve it.
at the mold level takes
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3. Change the mold direction using the Pull Direction option in the
effect at the part level.
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ASSEM SETUP menu.


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4. Create a rectangular workpiece using the Automatic Workpiece


dialog box. Enter the rectangular dimensions shown in
Figure 6–28.
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Figure 6–28
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5. Create a silhouette curve. The curve appears as shown in


Figure 6–29. The reference model has been blanked for clarity.

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Use Task 2 of exercise 5B


for reference.

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Figure 6–29

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The Skirt option is not 6. Create a skirt surface using the silhouette curve. Enter

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available in the SRF OPTS [OUTLET_PS] as the name of the skirt surface.
menu unless all
components are displayed. 7. Click Shade in the PARTING SURF menu. The skirt surface
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appears as shown in Figure 6–30.

Use Task 4 of exercise 5B


for reference.
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Figure 6–30
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Task 5: Split the model.

1. Split the mold into two volumes. Use OUTLET_PS as the parting
surface. Name the volumes [OUTLET_1] and [OUTLET_2].

2. Shade each volume. The volumes appear as shown in


Figure 6–31.

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OUTLET_2 OUTLET_1

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Figure 6–31

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3. Save the mold and erase all files from memory.
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Review Questions

Question 1 What is a mold volume?

Question 2 Does a mold volume contain solid geometry or surface geometry?

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Question 3 How do you create a split?

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Question 4 How do you specify which mold volume to assign a volume to if there
are more then two generated by the parting surface?

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Question 5 Which option in the Split dialog box can be used to convert the mold

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volume to curves to help resolve a split failure?

Question 6 -2 A
Describe in a few short sentences the most common causes of split
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failure related to your work.
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