Pro/ENGINEER provides many automated functions designed to help you create

injection molds using parts. There are two distinct Modes which allow you to
create the Mold Cavity from an existing Pro/ENGINEER part and then design the
Injection Mold Assembly.

The Mold Mode allows you to assemble your part and create the
cavity and core inserts. This Mode utilizes a manufacturing file
which contains a .mfg extension. This file is actually an assembly
with some specific additional functionality to make the design
process highly productive.

The Mold Mode contains functions to allow you to assemble the

plastic part and the raw insert stock into the file. It also allows you
to subtract the volume of the part from the inserts and cut the
inserts at a user-defined parting line.

The Mold Layout Mode allows you to assemble the cavity and core
inserts and a mold base to complete your design. This Mode also
allows you to specify an Injection Molding Machine (IMM) so that
you can design within the platen and tie bar clearances and align the
knock outs and loc ring. The Mold Layout Mode utilizes an
assembly file which contains a .asm extension. This Mode also
allows you to quickly create multi-cavity (e.g., 2-up, 4-up, etc.)
molds.

In general, you begin your design in the Mold Mode. To begin, you assemble the
existing part you want to mold.

Figure 1
As the part is assembled, the system creates a copy of the part which is called
the RefPart. This copy is fully associative to the original and you see no effect of
this being a copy, except that the RefPart can be modified without changing the
original.

Figure 2

This is an important point, since you will invariably change the RefPart as you
design the mold. The first significant change you make is to add Shrinkage to
the RefPart. Shrinkage can be added either by scale or by factor in the X, Y,
and Z axes of the part.

Once the RefPart is in place and Shrinkage has been added, you can create or
Assemble the Workpiece.

Workpiece

Figure 3

The Workpiece represents the raw material (e.g., steel) from which you will
create the mold inserts. These inserts may, as the design progresses, be left as
Mold Inserts or Merged with the A and B plates of the Mold Base.

The next step is to create a Parting Line Surface.

Parting Surface

Figure 4

Highly automated functions are available to help you in this process. The Parting
Surface is automatically created large enough to cut (Split) the entire
Workpiece.
When you Split the Workpiece into core and cavity halves, the system
automatically subtracts the RefPart from the Workpiece. The Parting Line
Surface then cuts the Workpiece into cavity and core.

Figure 5

You can make allowances for slides, lifters and core pins during this operation.

Once the cavity and core are designed, you enter the Mold Layout Mode to
create the assembly of the complete mold (cavities and mold base).
Figure 6

This Mode provides functions to quickly place the Manufacturing file (.mfg)
which you just designed in the Mold Mode.

Mold Layout also provides functions to define ejector pins, water lines, and mold
base Components.

Some practical points

Controlling the display of objects is very important in mold design for two
reasons. First, a complete mold can be a rather large assembly which may
become a performance problem. It is important that users who do a great deal of
mold design be equipped with a high end workstation. Second, you generally
create a large number of assembly level features when doing mold design.
Whenever you create a feature, the system allows you to identify which
components should be affected by the feature.

If you want the feature to affect all currently displayed components (that it
geometrically intersects) you can utilize the AutoAdd option. If you want only
certain components affected from those that are displayed, you must select each
of them each time you create a feature. Therefore, you will find it advantageous
to display only the affected components when you create features.

For example, when you are adding ejector pin clearance holes, you must create
holes in the core, the support plate, and the ejector bar retainer plate. The
process goes very quickly if you Blank/Hide every other component.

Core
Support Plate
Ejector Bar Retainer

Figure 7

This Course leads you through the process of designing several inserts, then an
A and B plate. You also design an insert which contains a slide. You will notice
that the parts are plastic injection molded parts and are simple yet actual molded
engineering models. Draft and radii are present where they are required to make
a practical, moldable part.

Some material thicknesses have been exaggerated to make selection and

visualization easier for your training. In addition, you may find that some of the
mold design parameters are not to your "liking." Every attempt has been made to
keep the molds as small as possible and to minimize complex displays.

At the end of the course, you will find a project. Very few instructions are
included in the project. You should apply your own mold design knowledge to
produce a proper design.

This Lesson quickly steps you through creating a fairly simple mold just to show
you the basic flow of the process (to design a mold).

There are two different Modes you utilize to design a Mold. These are the Mold
Mode and Mold Layout Mode. You begin in the Mold Mode by creating a
Manufacturing file with a Sub-Type of Mold Cavity.
Figure 1

Once the file is created, you add the part you want to mold.

Naming your Mold Design file.

The Mold Mode is designed to let you quickly create the core and cavity inserts
for your mold. The Mold Cavity Sub-Type automatically opens in the Mold
Mode. When you create a new file, you should consider using a Template.

Templates (i.e. start parts) are available to start your mold file. The default
system template contains default datum planes, a coordinate system, predefined
views and layers. Alternately, you can create your own custom template, or
choose to start with an empty file.

Once the file is open, you can place the part you want to mold. You can use two
options to place the part: Assemble or Locate RefPart. Assemble utilizes the
normal Assembly interaction to allow you place the part as a Component.

You need to use Assemble if the placement of the part requires the use of
Datum Planes or surfaces on the part or in the mold file.

Locate RefPart allows you to place the part by aligning its coordinate system
with a coordinate system in the mold file. Locate RefPart also allows you to
create an immediate pattern of the part in the mold file.
Figure 1

In this dialog, you can choose to create a copy of the design model using Merge
by Reference (the default). The system places an associative copy of the part in
the mold assembly. This copy is called the Reference Part. The system, by
default, names the ref part using the name of the mold file and the text _REF.

The other choice is Same Model, which will place the design part directly into
your mold assembly. Be aware that when you use the Same Model option, all
changes to the design part you make in Mold Mode (like shrinkage, draft, and
rounds) will appear directly in the design part.
By using the Merge by Reference option, you can effectively keep two versions
of the part alive, one in steel sizes (reference model), the other (the original) in
plastic sizes.

Exercise 1:

Objectives
Create a Mold Cavity file and add the part you want to mold.

Working Directory: mold

Figure 1

1. Create a new Mold Cavity file.

Choose File from the Menu bar

Choose New
Choose Manufacturing

Choose Mold Cavity as the Sub-Type

Type a name for the file. Include your initials and underscore:
(xxx_MFG0001)

This will also be the name of the manufacturing assembly that will contain the actual mold
components (as you add or create them). Remember, the Top Level file in Mold Mode is a
manufacturing file, but it contains an assembly to hold the mold parts. The mold file will have
a .mfg extension and the assembly will have a .asm extension.
Figure 2

Choose OK

2. Add the Reference Part (the part you want to mold).

Choose Mold Model

Choose Locate RefPart

Choose mold_part1.prt from the list in the Open dialog

Choose Open

The Create Reference Model dialog appears. Use the default Merge By Reference option
and enter the name of the Reference Model.
Figure 3

Type your initials_xxxxx_ref in the Reference Model Name text field

Choose OK

The Layout dialog now controls how many RefParts get added to the mold. The default
condition is to add a single part and align its coordinate system with the mold coordinate
system. This is just what you want in this case.

Figure 4

Choose OK from the Layout dialog

Figure 5

The system now check the Accuracy of the part in relation to the manufacturing file (which
you just created). If they do not match, the system will ask you if it is allowed to change the
Accuracy for the Reference part. This avoids any conflicts later on.

Choose Done/Return

Choose Done/Return

Adding Shrinkage

You can add shrinkage to the reference model once it is assembled into the mold
file. If you used the Merge by Reference option when creating the reference
model, then this change does not affect the original design part. You can add
shrinkage either by a Shrink Ratio (a.k.a., Scaling) or by adding it to all or
selected dimensions in the part.

By Dimension
By Scaling

Shrinkage can be applied using one of two formulas. One formula assumes that
the part is currently in its mold cavity state where the part is currently larger than
the required design model. This formula is:

1
1-S

The other formula assumes that the reference part is in the original design state
(the default). This formula is:
 1+S

These two options are available because in some applications (like casting), users
design the cast model first.

Figure 1

In both formulas, S is the value you enter the Shrink Ratio. (Note: negative
values are allowed.) One (1) is the size of the existing part to which shrinkage is
being applied.

You can apply shrinkage By Dimension to the entire model (All Dimensions),
or to selected dimensions or features. When you specify the shrink value for
individual dimensions, you can enter either the ratio or final value.
Figure 2

Note that the By Dimension option does not shrink external references or
imported geometry. Also, shrinkage By Dimension is not cumulative: if you
apply 0.005 to All Dimensions and then 0.010 to a specific dimension, the final
shrink value for that dimension is 0.010, NOT 0.015 (0.005 + 0.010).

You can also apply shrinkage By Scaling. You can specify different shrinkage
factors along the X, Y, and Z axes of the coordinate system you select. This
allows you to compensate for plastics that shrink more if the part is thicker in one
direction or is a great deal longer along a particular axis. Shrinkage By Scaling is
your only option if your design model contains imported (e.g. IGES) geometry.
There is no Update function for shrink By Scaling; it is applied only to the
reference model.

If the Isotropic option is checked, you can enter one Ratio which is applied
equally in all axes (or the coordinate system). If Isotropic is not checked, you
can enter independent values for X, Y and Z.
Figure 3

When you add Shrinkage, you create a feature.

Figure 4

To remove it, you simply Delete the feature. If you want to temporarily work on
the part without the Shrinkage, you simply Suppress the feature.

Use the Shrink Info option in the SHRINKAGE menu to review the status of
design model and all shrinkage values applied.
Figure 5

Exercise:

Objectives
Add shrinkage to the reference model.

If you did not complete the previous Demonstration and do not have the mold file open,
change the Working Directory to mold / moldupdate and open the file shrinkage.mfg.

1. Choose the formula that you are going to use.

Choose Shrinkage
Choose By Scaling
Choose the 1+S button (if it is not already chosen)

2. Apply the shrinkage to the model.

You need to specify a coordinate system in which can be used in calculating the shrinkage. As
the part changes size, the point at the origin of this coordinate system remains stationary.
Also, you want to avoid references to other parts as much as possible. Be sure that you
choose the coordinate system in the reference part.

Choose in the Coordinate System area if required

Select the coordinate system PRT_CSYS_DEF which is found at the center

of the RefPart
You can enter in different values in X, Y and Z if your design calls for it, but for now, use the
same value in all three axes. When the Isotropic option is checked, you enter one Shrink
Ratio. When this option is not checked, you can enter individual values in X, Y, and Z.

Type .005 as the shrink ratio and hit

Choose

Notice that a Shrinkage Feature has been added to the Model Tree. Note that you may
have to choose Settings/Tree Filters/Features to see the Shrinkage feature.

Figure 1

Choose Done/Return

Automatic Work piece

The Automatic option on the CREATE WORKPIECE menu allows you to quickly
create a workpiece by entering an offset distance around the Ref Part or by
specifying its overall dimensions.
Figure 1

When the Automatic Workpiece dialog displays, the system calculates an

imaginary box which encapsulates the Ref Part(s) and allows you to define the
workpiece as a series of offsets around this box.

Ref Part Workpiece Csys Workpiece

Parting Line

Figure 1
The orientation of the dimensions (in X, Y, and Z) are controlled by a Mold
Origin coordinate system which you must first select. The Z Axis of this
coordinate system should always be parallel to the direction of pull (i.e.,
perpendicular to the parting line), since the Core and Cavity height offsets are
always + and - Z values.

Figure 2

You can also Translate the origin of the Workpiece in the X and Y directions of
the Mold Origin csys.
Figure 3

You can create a workpiece based on 3 standard shapes.

Figure 4

You can only utilize the Automatic option if the Mold Base Catalog is installed
on your system. If the catalog is not installed, you will receive the error message:
no files or directories found.

If you receive this message, ask your System Admin to run the Pro/ENGINEER
Install and select the Mold Base Catalog component. Running the
Pro/ENGINEER install will not interfere with your existing installation, it will
simply add the catalog.

Exercise:

Objectives
Create a workpiece using the Automatic option.

Working Directory: mold

Figure 1

1. Create a workpiece which is 3 inches offset from the outside of the part.

Choose Mold Model

Choose Create

Choose Workpiece

Choose Automatic

The system displays the Automatic Workpiece dialog with the Mold Origin ( ) option
active by default.
Figure 2

Select the coordinate system called: MOLD_DEF_CSYS (note that is may be

hidden under PRT_CSYS_DEF)

Type 3 in the Uniform Offsets field and hit

Figure 3

The Uniform Offsets value gives you a quick way to specify the size of the workpiece,
unfortunately, it also makes the overall size of the workpiece rather odd. Now that you can see
that you have 3 inches of steel about the cavity, you can refine the Overall Dimensions by
entering more even numbers into the appropriate fields.
Figure 4

Double-click in the X text field and type 12

Double-click in the Y text field and type 12

Double-click in the +Z Cavity text field and type 5

Double-click in the -Z Core text field and type 4

Choose OK

Figure 5
Parting surface:

The Parting Surface is used to Split the Workpiece into cavity and core halves.
The Parting Surface is generally perpendicular to the Pull Direction and lies
between the parting line edges of the RefPart and the outside walls of the
Workpiece.

Figure 1

You can use two techniques to quickly create the Parting Surface in your mold.
You first use the Datum Curve / Silhouette option to create curves at the
parting edges of the RefPart. These curves are the basis of the Parting Surface
created by the Parting Surf / Skirt option.

A major portion of the effort involved in creating a Skirt Parting Line surface is
defining the silhouettes of the RefPart (parting lines). You can easily create
these curves using the Silhouette (Datum) Curve option.
Figure 1

You can create the curve on-the-fly, as part of the Skirt creation process, or you
can create a datum curve beforehand and simply select it when creating the
Skirt.

A Silhouette Curve is a datum curve. You find the Silhouette option on the
Datum Curve menu. When you choose this option, the system displays the
Curve dialog and prompts you to select surfaces upon which it should create the
Silhouettes. If there is only one RefPart in the mold, the system automatically
selects it and requires no more interaction. The Silhouette Curve dialog is
shown below.

Figure 2

The required elements are straight forward: a name, the target surfaces, and a
pull direction. The optional references control advanced functions to produce
quality parting curves on complex geometry. As said above, if there is only one
RefPart, the first three items will automatically set to Defined. In this case, you
create the curve by choosing the OK action button.
In this Lesson, you are going to create a simple set of Silhouette curves. In
future Lessons, you will learn how to utilize the more complex, optional functions
available with Silhouettes to create much more complicated Parting Surfaces.

Exercise:
Objectives
Create the Parting Surface for the mold.

Working Directory: mold

Figure 1

1. Create the Silhouette Curves on the RefPart.

Choose the Datum Curve icon ( )

Choose Silhouette

Choose Done

Choose OK in the Curve dialog

Since Silhouette Curves are often difficult to see (because they are along the edges of the
part), you may want to look to the Model Tree to note that the curve is created. Of course,
you will need to have Features checked in the Model Tree Items dialog.

Figure 2

2. Create the Parting Surface using the Skirt option.

Choose

The system now displays the Generate surface by filling loops and extending
boundaries (Skirt) icon. This option uses the Parting Line datum curve you created to
automatically split the workpiece.

Choose

Select the silhouette curve you created in the previous Step

Figure 3

Choose Done from the CHAIN menu

Choose OK in the Skirt Surface dialog

Figure 4

Choose
Creating Cavity and Core:

There are two steps involved in creating your core and cavity inserts from the
Parting Surface, RefPart and Workpiece. You first Split the Workpiece using
the Parting Surface. During the Split, the system subtracts the RefPart from
the Workpiece, then it cuts the remainder (of the Workpiece) with the Parting
Surface.

Figure 1

The Split creates two Mold Volumes. You turn these volumes into the cavity and
core mold components (parts) using the Extract option.

When you Split the workpiece, the system automatically subtracts the reference
part from the workpiece. It then splits the remaining material along the parting
surface.
Figure 1

Initially, you can Split the workpiece into two volumes using the Two Volumes
option. If the parting surface intersects any of the molding surfaces, it will
generate more than two solid bodies. In this event, the system will highlight each
volume, in turn, and ask you to assign it to either the first volume or the second
volume. This process is called Classifying.

In other words, depending upon the shape of the workpiece, the shape of the ref
model, and the shape of the Parting Surface, the Split may create several solid
bodies, which must end up as part of two volumes (when you use the Two
Volumes option).

When the Split occurs, the system asks you to assign a name to each volume.
The system creates a mold volume with the name you specify. When several
bodies are assigned to the same volume, they are merged together (if possible).
Even if they are not merged, all of the specified solid bodies will belong to the
volume.

Mold Volumes are separate solids created during the Split. However, these
volumes are not separate components (as you require the cavity and core to be).
You can automatically create components from these volumes using the Extract
option. The Extract option creates a new part for each volume. These parts are
components in the mold assembly and are located in space by the Split.
Therefore, they do not need to be assembled using the normal assembly
constraints.

By default, the new parts have the same names as the volumes from which they
were created. You have an opportunity to rename the part and include a template
under the Advanced tab of the Create Mold Component window.
Figure 2

Once you extract the volumes into components, they become parts in the
assembly. When you save the assembly, the new components are also saved.

Work Out:
Objectives
Create the cavity and core inserts.

1. Split the Workpiece using the Parting Surface.

Choose

Choose Done to accept the defaults on the SPLIT VOLUME menu

Select the parting surface

Figure 1

Choose OK

Choose OK in the Split dialog

The system now displays the Volume Name dialog and highlights one of the volumes in the
graphics area.

Figure 2

The system is asking you to name the highlighted volume. You will get the chance to also
name the other volume in a minute.

Choose OK in the Volume Name dialog to accept the default name

The system creates the first volume. Note that the edges of the lower portion of the mold
have changed to magenta. The other volume is highlighted in cyan.

Choose OK in the Volume Name dialog to accept the default name

Take a look at the Model Tree to see the features you have created to be able to construct
the cavity and core.

Figure 3

Choose Done/Return

2. Extract the mold volumes into cavity and core components.

Choose Mold Comp

Choose Extract

The system displays the Create Mold Component dialog.

Figure 4
 Choose the Select All icon ( )

Choose Ok

When you use the Select All option (or when more than one volume in the list is selected)
the system automatically creates the parts and automatically names them.

Figure 5

Choose Done/Return

Knowledge Check: