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Mold Design
Reference Guide

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CONTENTS
1. Introduction to Basic Mold . ... ..... ........ .. .. ... ... ...... . ..... .......... .
.. . . ........ ..... . . .. . ..... . .. .. ........... .. .. . 3 . .

Basic about Mold ......................... ..................... ................... ... ... .......................................................

. ............... ............... 3
Applications ....................................................................................................................................................................... 4

Mold manufacturing processes ...... .... .-....................-................................................................................................... 4

Machining ..................................................... ........................ . .................................. .................. ........................................ 4

Plastic materials .
.................................................................. ............................................................................................ 5

Molding Machine .
.. ... ..................... ........ ............................ .. ........ . . ....................................................... ... .................... ... . 7

Molding Process ...................................... . .

.............................. ......................................................... .......... ...................... 9

Mold t'f?tC:. ..................................................................................................................... .................................................. 1()

Parts of mold . .
...... ................................. ... ....................................... ..... ..... . .......... .. ................................... ...................... 16
Single Cavity mold ........................................ ................................................................................................................. 21
Multy cavity mold . .......................................... ......... . ............... .:::··································· .
............. ............ ...................... 21
Family Mold .
...................... ........................................................................................... ............................................. ..... 22
Side Core Et Side Cavity .................................... . .......................................................................................................... 22

Methods of actuation .
...................................... . ..... ......... ... . . .
..... ...... . ..................................................... . ................ . .... 22
Feed system ................... .................. ................................................................................................................................ 23
Shrinkage .......................................................................... ..... . ............ . .
...................... ........................ ............................. 27
Ejection . .
.......... .. ............ . . .
.......... .. .
....................................... ................................................ ............................................ 27
Draft ................................................................................................... ............................................................................... 29

Parting surface .................................................................................................................... .......................................... 30

2. Reference Model creation .......... . .. ............. ...... ...... .. ... .. . . .. .... . ... .. .
.. . .. . .. . . . .. ... .. .
... .. . . ... . ... 35
. .. . .. .

Creating Rib Features ............................................................................................................... . . ............ . ....................... 35

Creating Draft Features . . .
.......... ................. ........ ......................................................................................................... 37
Analyzing Draft Hinges and Pull Direction .......................... ............... .
. ....................................................... .......... . 41
Design Model Analysis .
................ ...................................................................................................... ......................... . 48

Mold Model . .
..... ............................................. ............... ......... .................... .. ....... . . ......... ....... .......................................... 54
Modifying the Default Pull Direction . ............................................................................................................... . ...... 56
Analyzing Model Accuracy .. .............................................................................................................................. ......... 59

Creating the Reference Model ....................................................................... ................ . ......................................... .. 62

Redefining the Reference Model ............................................................................................................................... 67
Analyzing Mold Cavity Layout . .
................ ........................................ ..... .................... ................................................ 72

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3. Preparing Mold Mode l s ·······································------- ····· ................ 91

S hrinkage .................................................................................................. .-------····················· 91

.

Workp iece................................................................................................................ ....................... 102

Recl assify ing Mol d Model C omp onents . . ..
...................... .......................................... .... . .
_______. .. ................. 110
Mol dVol ume C re ation............................................................................................................................................... 113
C reating S liders ............................................................................................................................................................ 117
Re fe re nce Part: C utout ..................................................... :......................................................................................... 129
Lifter Mol dVolumes................................................................................................................................................... 132
S ke tching Inse rt Mol dVol ume s.............................................................................................�................................ 142
Parting Line andParting S urfaceC reation.......................................................................................................... 148

4. Creating Mold ...................................................................................................................... 217

Spl itting the Workp ei ce ............................................................................................................................................. 218

Spl itting MoldVol umes ............................................................................................................................................. 221
Blanking and Unbl anking Mol d Ite ms................................................................................................................... 231
Analy zing SplitCl assification .................................................................................................................................. 236
Mol d C omp one nt Extraction .................................................. ................................................................................... 241
Mold Features C reation............................................................................................................................................. 246
Waterl ine C ircuits....................................................................................................................................................... 246
C re ating Sp rues and Runners ............................................... ................................................................................... 258
Ejector Pin Cl earance Hol e s ..................................................................................................................................... 266
Fil l ing andOp ening theMold.................................................................................................................................. 279
Op ening the Mol d....................................................................................................................................................... 281
DraftC hecking a MoldOpe ning S tep ................................................................................................................... 288
Inte rfe re nce C hecking a Mol dOp ening S te p .................................................. .................................................... 292
Vie wing Mol d Information................................ ....................................................................................................... 295.

5. Project ···············································-······-··-·-·····································--······································ 321

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0 Basic about Mold

0 Mold manufacturing processes

0 Machining

0 Plastic materials

0 Molding Machine

0 Molding Process

0 Mold types

0 Parts of mold

0 Single Cavity mold

0 Multi cavity mold

0 Family Mold

0 Side Core a Side Cavity

0 Methods of actuation

0 Feed system

0 Shrinkage

0 Ejection

0 Draft

0 Parting surface
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1.lntroduction to Basic Mold

Basic about Mold

Mol ding(BritishEngl ish: moulding) is a manufac turingp roc ess forp roduc ingp arts from both thermop lastic
and thermosetting pl astic material s. Molding is the p roc ess of manufac turing by shap ing pl iable raw
material using a rigid frame or model c alle d a p attern.
Amold is a holl owe d-out bl oc k that is fille d with a l iquidl ikepl astic , glass, metal, orc eramic raw material s.
The liquid harde ns or sets inside the mol d, adop ting its shap e. A mol d is the opp osite of a c ast. The
manufac ture r who makes the molds is c all ed the mol dmake .r A rel ease age nt is typ ci ally use d to make
removal of the hardened/set substanc e from the mol d easier.

Fig 1.1 : Mold Component.

History

In 1868 John We sley Hy att devel op ed a pl astic mate rial he named Celluloid whic h had be en inve nted in
1851 by Ale xande r Parks. Hy att imp roved it so that itc oul d be p roc essed into finished form. In 1872 John,
with his brother Isaiah, p atented the first injec tion mol ding mac hine. This mac hine was relatively simp le
c omp ared to the mac hine s we use today. It basic ally worke d l ike a l arge hyp odermic needle injec ting
pl astic through a heated cyl inde r into a mold. The industry p rogre ssed sl owly over the y ears p roduc ing
p roduc ts suc h as c oll ar stay s, buttons, and hairc ombs until it expl odedin the 1940s bec ause WorldWar 2
c reated a huge de mand for inexp ensive, mass-p roduc ed p roduc ts. The industry has evol ved ove r the years
from p roduc ing c ombs and buttons to p roduc ing a vast array of p roduc ts for many industries incl uding
automotive , medic al , aerosp ac e, c onsume r, toy s, p lumbing, p ac kaging, andc onstruc tion.

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Applications

Injection molding is used to create many things such as mil k cartons, containers, bottl e cap s, automotive
dashboards, p ocket combs, and most other p l astic p roducts avail abl e today. Injection mol ding is the most
common method of p art manufacturing. It is ideal for p roducing high volumes of the same object. S ome
advantages of injection mol ding are high p roduction rates, high tol erances are rep eatable, wide range of
material s can be used, l ow labour cost, minimal scrap l osses, and l ittl e need to finish p arts after mol ding.
S ome disadvantages of this p rocess are exp ensive equip ment investment, running costs may be high, and
p arts must be designed with mol ding consideration.

Fig 1.2: Application

Mold manufacturing processes

Mold is the common terms used to describe the tool ing used to p roduce pl astic p arts in mol ding.
Traditionally , mol ds have been exp ensive to manufacture. They were usually only used in mass p roduction
where thousands of p arts were being p roduced. Molds are typ ically constructed from hardened steel , p re­
hardened steel , al uminium, and/or beryl lium-copper all oy. The choice of material to build a mol d from is,
p rimarily one of economics, steel mol ds generally cost more to construct, but their longer l ifesp an will
offset the higher initial cost over a higher number of p arts made before wearing out. Pre-hardened steel
mol ds are l ess wear resistant and are used for lower vol ume requirements or l arger comp onents. The mol ds
can be manufactured by either CNC machining or by using El ectrical Discharge Machining p rocesses. ·

Machining

Mol ds are built through two main methods: Standard machining and EDM. S tandard Machining, in
its conventional form, has historically been the method of buil ding injection molds. With technol ogical
devel op ment, CNC machining became the p redominant means of making more compl ex mol ds with more
accurate mol d details in l ess time than traditional methods.

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The elect ricaldischarge machining(EDM) or sp ark erosionp roc ess has bec ome widety used·n fT'Ol1J croking.
As well as all owingt he format ion of shap es which are diffic ult t o mac hine, thep rocess alto'IS pre-r.aroe_reo
mol ds to be shap ed so t hat no heat t reat ment is required. C hanges t o a hardened mol d by convo..n!iona
drill ing and mil l ing normally require anneal ing t o soft en t he st eel , foll owed by heat t reatmentto haroen
it again. EDM is a simpl e p rocess in whic h a shap ed el ect rode, usually made of copper or grap hit e, isvery
slowly lowered ont ot he mol d surface (over a p eriod of many hours), whic h is immersed in p araffin oil. A
volt age appl ied bet ween t ool and mol d causes sp ark erosion of t he mol d surface in t he inverse shap e of
t he el ec trode.

Fig 1.3: Machining processes

Plastic materials

Pl ast ic is sy nt het ic p oly mer of high mol ecul ar weight. It is comp osed of organic chemical unit s. Poly mer
is a single l arge mol ecul e. It is formed as a result of t he union of t wo or more mol ec ules of simpl er
substance.
Plast ic are normal ly cl assified int o2 c at egories:

Plastics

Thermoplastics Thermosetting

Fig 1.4: Type of Plastics.

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Thermoplastic
A thermoplastic is a polymer that turns to a liquid when heated and freezes to a very glassy state when,
cooled sufficiently. Thermoplastics are elastic and flexible "thermoplastic materials can be remelted without
'
undergoing any appreciable chemical change and you reuse"
Thermoplastics materials are as follow:
• Polypropylene (PP), Ex: Automobile components etc...
• Polystyrene (PS), Ex: Toys, Paper weight etc...
• Polycarbonate (PC), Ex: Helmets etc...
• Polyamide (PA). Ex: Ropes, gears etc.. .
0 Properties

The following are the properties of thermoplastic :

• Possesses high glass sparkle.
• Transparence.
• High mechanical crack resistance.
• Soft and flexible.
Thermosetting
Relating to a compound that's softens when initially heated, but hardens permanently once it has cooled.
Thermosetting materials are made of long-chain polymers that cross-link with each other after they have
been heated, rendering the substance permanently hard. Thermosetting materials can not be remelted and
you can not reuse.
Thermosetting materials are as follow:
• Polyurethane
• Alkyds, Ex: Pressure vessels, jigs & fixtures etc...
• Polyesters, Ex: Automobile parts etc...
• Epoxies, Ex: Switches, Connectors etc. ..

0 Properties

The following are the properties of thermosetting plastic:

• High Thermal stability.
• High dimensional stability.
• High rigidity and hard ness.
• Light weight.

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Molding Machine

TheMold designer should know the typ es of molding mac hine are avail able with his c ustomer as this will
infl uenc e his mold design. You must al so know the c ap abil ities of the mac hines and whether the mac hine
c an be expl oited bey ond the ratedc ap ac ities if the need areas.

fig 1.5: Molding M/C

A modern injec tion mol ding mac hine c onsists of foll owing basic part:

Feed

Nozzle Barrel heater

Screw drive
arrangement

Screw tip Checkvalue Screw

fig 1.6: Mold M/C Injection system

Hopper
A feed hopper is for hol ding and feeding the pl astic material in to barrel.
Barrel
Barrel is acyl indric al shel l or tube. In diameter of the barrel guides the extrude sc rew. Heaters are cl amp ed
on external diameter.

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Extrude screw

The screw of an i njection m o l d i n g mac h i n e is d ivided i nto th ree sections or zones.

• The feed section.

• The com pression secti o n .
• The m eteri n g secti o n .

T h e feed section tra nsports the p lastic m ateri a l from the h o p pe r t o heated portion o f the barrel. The p l astic
g ra n u l e is com p ressed to a homogeneous melt in the com p ress i on section:"

The fi n a l m ixi n g a n d heating of the material i nto a h o m og e n eous m e l t is ca rried o u t in the m eteri ng zone.
The d rive fo r the rotation of screw d u r i n g feed cyc l e is obta i n ed from a hyd ra u l ic m otor or a va ria b l e speed
el ectric m otor.

Fig 1 . 7: Extrude Screw.

Nozzle

The Nozz l e i s co n n ected to the end of th e ba rrel. Th rou g h the nozzle the softened material passed i nto the
mould. Genera l p u rpose or sta n d a rd nozzles a re made.

F i g 1 .8 : Nozzle.

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Molding Process

The chart below explains the Molding process.

Assigning • mold number

J.
Moking a production flow
chart by computer

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1.20draw1ng -----.

....------'I'---
:+: ----
2.Assemblong drawing ---.
3.Drawing sketch

-1-
4.Cmverttng to NC program

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Mold design -
5.30 CAD

+ Confirm l1011 by cJstome•

6.30CAM

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.-- Material preparation
O u n with tm

L
Mo'd desig!l review

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Process.ng techoology �

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·�---
Mold making - 1.Mold·base molding
---- -----
2.CNC machining
3.lnner cord mach1n1ng
4.Heat treatment
5.Machlng after heat treatment
6.Electrode process
7.Wore cut
8.E.D.M.
9.lnterior POllshment

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Fig 1.9: Molding Process Chart.

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Molding

Different processes of Plastic Moldings:

• Blow molding
• Extrusion
• Thermoforming
• Calendaring
• Reinforced plastics
• Reaction injection molding
• Injection molding
• Compression molding
• Transfer molding
Blow molding
Blow molding is intended for use in manufacturing hollow plastic products It is a process used to produce
hollow objects from thermoplastic. In general, there are three main types of blow molding: Extrusion blow
molding, injection blow molding, and stretch blow molding.
The blows molding process begins with melting down the plastic and forming it into a parison or perform.
The parison is a tube-like piece of plastic with a hole in one end in which compressed air can pass
through.
The basic process has two fundamental phases. First, a perform (or parison) of hot plastic resin in a
somewhat tubular shape is created. Second, a pressurized gas, usually air, is used to expand the hot
preform and press it against a female mold cavity. The pressure is held until the plastic cools. This action
identifies another common feature of blow molded articles. Part dimensional detail is better controlled on
the outside than on the inside, where material wall thickness can alter the internal shape. Once the plastic
has cooled and hardened the mold opens up and the part is ejected.
a

(j

t.

Fig 1.10: Blow Mold -

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Extrusion
Extrusion moul ding is a manufac turing proce ss use d to make pipe s, hose s, drinking straws, c urtain trac ks,
rods, and fibe rs.
The mac hine use d to e xtrude mate rial s is ve ry simil ar to an injec tion moul ding mac hine. A motor turns
a sc re w whic h fee ds granule s of pl astic through a he ate r. The granule s mel t into a l iquid whic h is force d
through a die , forming a l ong 'tube l ike ' shape. T he shape of the die de te rmine s the shape of the tube . T he
e xtrusion is the nc oole d and forms a sol id shape. The tube may be printe d upon, andc ut at e qual inte rvals.
The piece s may be rolle d for storage or pac ke d toge the r. S hape s that c an re sult from e xtrusion incl ude
T-sec tions, U-sec tions, square sec tions, I-sec tions, L-sec tions andc irc ul ar sec tions.

Fig 1.11 : Extrusion mold.

Injection molding
Inje ction mol dingis a manufac turing proce ss for produc ing partsfrom boththermoplastic andthermosetting
pl astic mate rial s. Mate rial isfe d into a he ate d barre l, mixe d, andforce d into a mol d c avity whe re itc ool s
and harde ns to the c onfiguration of the mold c avity. Afte r a produc t is de signe d, usually by an industrial
de signe r or an e nginee r, mol ds are made by a mol dmake r (or tool make r) from me tal , usually e ithe r steel or
aluminium, and prec ision-mac hine d to form the fe ature s of the de sire d part. Injec tion mol ding is widely
use d for manufac turing a varie ty of parts, from the smallestc ompone nt to e ntire body panel s of c ars.

Injection Mold (VERTICAL TYPE)

Oj>emOI)
Sprue Bar Slot

Dowel Pin
&. Bush111g

Trim G
ate

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Calendaring
The calendaring process is a continuous, synchronized method for converting raw material into a flux and
then handling the plastic like mass through the nips of a series of cooperating rolls into a sheet of specified
thickness and width.

Fig 1.13: Calendaring

Thermoforming
The thermoforming process consists of heating thermoplastic sheet to its softening temperature and forcing
the hot and flexible material against the contour of the mold by mechanical (Ex: Tools, plugs, Solid molds.)
or by Pneumatic means air pressure created by pulling a vacuum or using the pressure of compressed air.
When the mold is cooled the plastic retains the shape and details of the mold.

@ Colored Sheet
is Pre Heated
@ Pressure and
Vacuum are
@ Part is Removed
Trimmed and
to Soften for Applied to Machined to
Process Form Part Complete

Fig 1.14: Thermoforming.

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Reaction injection molding

Reaction injection molding (RIM molding) is similar to injection molding except that a reaction occurs
within the mold. The process uses thermoset polymers (commonly polyurethane) instead of thermoplastic
polymers used in standard injection molding. Before injection of the polymer two components are mixed
which react in the mold to form a solid thermoset polymer. The bi-component fluid is of much lower
viscosity than molten thermoplastic polymer which enables the economical production of large parts with
complex geometry.

3 4

Fig 1.15: Reaction Mold

Compression molding
Compression molding is a method of molding in which the molding material, generally preheated, is first
placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is
applied to force the material into contact with all mold areas, while heat and pressure are maintained
until the molding material has cured. The process employs thermosetting resins in a partially cured stage,
either in the form of granules, putty-like masses, or performs. Compression molding is a high-volume,
high-pressure method suitable for molding complex, high-strength fiberglass reinforcements. Advanced
composite thermoplastics can also be compression molded with unidirectional tapes. woven fabrics,
randomly orientated fiber mat or chopped strand. The advantage of compression molding is its ability to
mold large, fairly intricate parts. Also, it is one of the lowest cost molding methods compared with other
methods such as transfer molding and injection molding; moreover it wastes relatively little material,
giving it an advantage when working with expensive compounds. However, compression molding often
provides poor product consistency and difficulty in controlling flashing, and it is not suitable for some
types of parts. Compression molding produces fewer knit lines and less fiber-length degradation than
injection molding. Compression-molding is also suitable for ultra-large basic shape production in sizes
beyond the capacity of extrusion techniques.

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Upper mold half

Lower mold half

Gravity
..

...,
__ Knock-out pin

(1) (2) and (3)

(4)

Fig 1. 16: Compression Mold.

Transfer molding
Transfer molding, like compression molding, is a process where the amount of molding material (usually
a thermoset plastic) is measured and inserted before the molding takes place. The molding material is
preheated and loaded into a chamber known as the pot. A plunger is then used to force the material from
the pot through channels known as a sprue and runner system into the mold cavities. The mold remains
closed as the material is inserted and is opened to release the part from the sprue and runner. The mold
walls are heated to a temperature above the melting point of the mold material; this allows a faster flow
of material through the cavities.
Transfer Molding is an automated operation that combines compression-, molding, and transfer-molding
processes. This combination has the good surface finish, dimensional stability, and mechanical properties
obtained in compression molding and the high-automation capability and low cost of injection molding
and transfer molding. Transfer Molding is having a "piston and cylinder"-like device built into the mold so
that the rubber is squirted into the cavity through small holes. A piece of uncured rubber is placed into a
portion of the transfer mold called the "pot." The mold is closed and under hydraulic pressure the rubber or
plastic is forced through a small hole (the "gate") into the cavity. The mold is held closed while the pla�tic
or rubber cures. The plunger is raised up and the "transfer pad" material may be removed and thrown away.
The transfer mold is opened and the part can be removed. The flash and the gate may need to be trimmed.
Another key point is that a premeasured amount of thermosetting plastic in powder, preform, and even
granular form can be placed into the heating chamber.

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Fig 1.17: Transfer Mold

Rotational molding
Rotational mol ding is a versatil e p roce ss for creating many kinds of mostly hollow pl astic p arts. The
p hrase is often shortened to rotomolding.

A heated mol d causes the pl astic resin within to melt andform a p uddl e at the bottom of the mold cavity.
The mold is then sl owly rotated(usually around two p erp endicular axes) causing the mel tedp lastic to fl ow
into to the mold and stick to its wal l s. In order to maintain even thickness throughout the p art, the mol d
continues to rotate during the cool ing p hase.

Rotational molding

Powder Mold

char9in9

0
Fig 1.18: Rotational Mold

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Parts of mold

The following are the basic parts of mold:

• Core insert
• Cavity insert
• Core retainer or core plate
• Cavity retainer or cavity plate
• Back plate
• Parallel block
• Ejector plate
• Ejector retainer
• Ejector pin
• Return pins
• Rest buttons
• Ejector rods
• Ejector rod bush
• Sprue bush
• Sprue puller
• Register ring
• Guide pillers
• Guide bushes
Core insert
This is a male part in mold and projects in a mold and projects from the core plate. It forms internal shape
of the component.

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Cavity insert
This is a female part of a mold and has hollow in the cavity plate. It forms external shape of the
component.

Fig 1.20: Cavity Insert.

Fig 1.21: Core a Cavity insert Assembly.

Core retainer or core plate

engaged in opening I closing movement is called a core plate. The
It retain core insert. The section that is
core plate leaves a trace on a part, because it has an ejector pin to pu sh the part.

Fig 1.22: Core plate.

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Cavity retainer or cavity plate

It retains Cavity insert. The cavity plate has a sprue bush, which is the entrance for molten plastic.

Fig 1.23: Cavity plate.

Back plate
These plates are placed bottom of the core plate and over the cavity plate. These plates do not allow the
core and cavity insert to come out of the core and cavity plates.

Ejector plate
This is placed to bottom of ejector retainer and clamped together this does not allow the ejector pins and
return pins to come out from ejector retainer. This has provision to hold the ejector rod. This plate transmits
the force from the actuating system of the injection machine to the molding via an ejector rod.

Ejector retainer
This Retains the ejector pins and return pins.

Fig 1.24: Ejector Plate and Ejector retainer.

Paral lel block

These plates provide enough space to operate the ejection system.

Height of the parallel block =Thickness of the ejector assembly + Thickness of the rest buttons head +
required movement.

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Ejector pin

The ejector pins are fixed from ejector retainer to core plate. This ejector pin is to eject components from
core insert.

Fig 1.25: Ejector pins

Return pins
This allows ejection system to move back into rear position when mold is getting closed. Initially return
pins comes in contact with the cavity plate of fixed half and allows ejection system to move back.

Rest buttons
These are fixed to bottom plate or bottom of ejector plate. Rest buttons reduces the effective seating area
of ejector plate.

Fig 1.26: Re.st buttons.

Ejector rods
The ejector rod is attached to the ejector plate by means of thread. It helps to move ejection system.

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Sprue bush
This is a tapered hole this works as passage between nozzle of the macnfoe a:-o t".J"'ner of the mould. It is
fixed in top plate of the mold.

Fig 1.27: Sprue bush.

Sprue pul ler

When the mold opens it is essential that the sprue is pulled positively from the sprue bush. Sprue puller is
provided to pull the sprue in case of multy cavity mold.

Register ring
The material is to pass without hindrance into the mold. The nozzle and the sprue must be correctly
aligned. Register ring aligns the mold to center of machine.

Guide pillers
Guide pillers are fixed in cavity plate or top plate in fixed half. These are used align Fixed half and movable
half.

Guide bushes
Guide bushes are fixed in core plate in moving half. These are used align movable half and Fixed half.

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Mold assembly

The following picture shows simpile mold assembly

Fig 1.28: Mold Assembly.

Single Cavity mold

In this we will have only single core and cavity. You produce only one component at a time.

Fig 1.29: Single Cavity mold

Multy cavity mold

If you create more than two or more cavity is called multy cavity mold.

Number of cavities: Ones the order is finalized and the design is going to start, the discussion should be
weather Single cavity or multy cavity mold should be used. Points to be taken into consideration:

• Number of components to produce and period of delivery.

• Injection molding machine and machine capacity (Tonnage).
• Cost of molding.

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Family Mold

In one mold create two or more different components.

Fig 1 .30: Family mold.

Side Core a Side Cavity

Side cores are used for forming a hole or recess in the side face of a component. It is normally mounted
on at right angle to the mold axis.

Side cavity is used for the formation of projections in the side face of molding.

The side cavity must be with drawn prior to ejection.

Advantages:
• The mold is simple and there fore less expensive.
• Ease of operation and less production difficulties.
• No flow line will develop.
I

Fig 1 .31 : Side core.

Methods of actuation

The side core or side cavity assembly is actuated by three methods:

• Finger cam.
• Dog leg cam.
• Spring actuation.

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Finger cam method of when a short delay period is required. The amount of clearance between cam and
cam hole determines the delay time. The finger cam should be sufficient length to withdraw the side core
completely from the molding.

The dog leg cam method is used when a longer delay period is required. It is desirable to withdraw the
molding completely from the fixed half before retracting the side core. This ensures that the molding
remains in the moving half in readiness for ejection.

The spring loaded system is used for molding with shallow undercuts or projections.

Fig 1.32: Cam Actuation.

Feed system

It is necessary to provide a flow way in the injection mold to connect the nozzle of the injection machine
to the impression. The floe way is termed as feed system. Normally a feed system consists of a sprue, runner
and gate.

It is seen that the material passes through the sprue, main runner, branch runner and gate before entering
the impression.

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Sprue
Sprue is the element, which carries the material from the machine nozzle to the ru nner or impression.
Normally it fixed in the top plate. Tapered hole in the centre of the mould into which the molten plastic
is first injected.

Fig 1.33: Sprue.

Runner
Runner is passage ways in the mould connecting the cavities to the sprue bush. The wall of the runner
should be smooth to prevent any restriction of flow. Also the runner should be removed from the molding.
Runners should polish (glass finish).

While designing runner the following points to be considered:

• It should be small as possible

• It should be equal in length to all cavities.
• It should ensure simultaneous filling of all cavities.

Fig 1.34: Runner.

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Layout of runners
Shape of runner in mold is usually:

• Fully round
• Trapezoidal
• Rectangle
• Square

Conventional Improved Balanced "H" Circular

Fig 1.35: Runner layout.

Machining and ejection of square and round are difficult. To overcome the problems trapezoidal runners
are mostly designed.

Fig 1.36: Runners. /

Gates
Gate is connecting runner to cavity. Its cross section is very small when compared with the other feed
systems. Frequently the runner narrows as it enters the mould cavity. This is called a gate and produces a.
weak point enabling the moulding to be easily broken or cut from the runner.
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A gate should be designed such that:

• Freeze soon to avoid suck back: When the nozzle is taken back after injection, the material from
cavity should not tend to go back to the runner.
• Easy degating: Breaking the component from runner should be easy.
• Small witness mark: The gate should not leave a witness mark on the component
• Better control over flow rate: Gate dimension can be adjusted to achieve better flow and filling
rate.

e Type of gates

• Centre gate

• Edge gate

• Rectangle gate

• Ring gate

• Over lapping gate

• Self cutting gate

molding

runner

I
branch runner
Fig 1.37: Gate Fig 1.38: Feeding system

Cooling
Hot material is injected into the mold. It cools rapidly to a temperature at which it solidifies to retain the
shape of the impression after ejection. The temperature mold has a major influence on the mold cycle time.
Melt flows freely in a hot mold. But grater cooling period is required. If the mold cools quickly the melt will
not reach the extremities of the impression.

To maintain the required temperature water is circulated through holes or channels within the mold. These
holes or channel are termed water ways. The complete system of water ways is termed as circuit.

It has both inlet and outlet.

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Fig 1 .39: Cooling Holes

Shrinkage

The incremental difference between the dimensions of the molding and the mold from which it was made,
expressed as a percentage of the dimensions of the mold.

When a molding cools, it contracts by amount depending on the material being processed. Each material
has its own characteristics shrinkage. The chart gives the perce�tage of shrinkage for some of the commonly
used material.

Shrinkage increases with:

• Increase of material temperature.

• Increase of mold temperature.
• Increase in section thickness.

Shrinkage decreases with:

• Higher cavity presser.

• Longer injection time.

Shrinkage formula

Shrinkage = Dimension X 0.5/100

Ejection

Ejection is to eject the mold component from core. The method of ejection has to be adapted to the
shape of the molding to prevent damage. In general, mould component is stuck by shrinkage of the part
on the mould cores. large ejection areas uniformly distributed over the molding are advised to avoid
deformations.

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Several ejector systems can be used:

• Ejector pin or sleeve

• Blades

• Air valve
• Stripper plate

• Thread ejection

Ejector pin or sleeve

When no special ejection problems are expected, the standard ejector pin will perform well. I n case of
cylindrical parts like bosses a sleeve ejector i s used to provide uniform ejection around the core pin.

Blades
Blades are poor ejectors for a number of reasons: they often damage parts; they are prone to damage and
require a lot of maintenance. Blade ejectors are most commonly used with ribbed parts.

Fig 1.40: Ejection System.

Air valve
A central valve ejector is frequently used in combination with air ejection on cup or bucket shaped parts
where vacuum might exist. The air valve is thus only a secondary ejection device.

A high-gloss surface can have an adverse effect on mould release because a vacuum may arise between cavity
wall and the molding. Release can be improved by breaking the vacuum with an ejection mechanism.

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Stripper plate
A stripper plate or ring is used when ejector pins or valves would not operate effectively. The stripper plate
is often operated by means of a draw bar or chain.

Thread ejection
When the threaded component is to eject it makes core to rotate. This is done by connecting gear from
rotating member to the ejector pins, rack and pinion etc.

Draft

A draft angle describes the amount of taper for molded parts perpendicular to the parting line.
Consider the fabrication of a hollow plastic box, without lid. Once the plastic has hardened around the
mold, the mold must be removed. As the plastic hardens, it may contract slightly. By tapering the sides of
the mold by an appropriate "draft angle", the mold will be easier to remove.

If the mold is to be removed from the top, the box should taper in towards the bottom, such that measuring
the bottom internal dimension will yield a smaller length and width than measuring the top from which
the mold is extracted.

By specifying the opening length and width, a draft angle, and a depth, it is not necessary to specify the
dimensions for the internal surface, as these may be calculated from the above.

The manufacture of a part that incorporates zero or negative angles may require a mold that can be
separated into two or more parts, in order to release the molding.

Undrafted Drafted

Fig 1.41 : Draft.

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Parting surface

The portions of both the mold plate which butt together is the parting surface, the parting surface forms
a seal and prevents the loss of plastic material from the impression.

Parting surface are classified as flat and non flat. The non flat parting surface includes stepped, profiled
and angled surfaces.

The nature of parting surface depends on the shape of the component. A parting surface must be so chosen
that the molding can be ejected easily from the mold.

It the parting surface are not properly matched the material from the impression will escape through the
gap. This material is called Flash.

Platen

Fig 1.42: Parting Surface.

Conclusion

With the information from this chapter it is hoped that reader gained more about Mold, Mold machine, -
Plastics, Different type of molds, Mold and it parts, Functions of mold etc. Hope after learning this chapter
you are familiar with mold concepts. In next chapters you will learn about how to create these Core, Cavity,
·
Runners etc ... in Pro/ENGINEER soft ware.

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0 Creating Rib Features

0 Creating Draft Features

0 Analyzing Draft Hinges and Pull Direction

0 Design Model Analysis

0 Mold Model

0 Modifying the Default Pull Direction

0 Analyzing Model Accuracy

0 Creating the Reference Model

0 Redefining the Reference Model

0 Analyzing Mold Cavity Layout

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2. Design Model Creation
In this chapter, you will learn about the basic mold process in Pro/ENGINEER that is typically used to take
a part from its design stage to the creation of its mold.

P reparing and Analyzing Design Models

When you create a mold for a design model, you should first inspect the model and analyze it to verify that
it is indeed ready to be molded. Typically, the reference model geometry that you use for a mold model is
derived from the design model. You can analyze the design model and reference model for adequate draft
features and consistent thickness, adding draft features if necessary. It is critical that the final reference
model should have sufficient draft, so that it can be cleanly ejected from the mold.

Even though the design model you receive may be a valid design model, you may not be able to use the
model to create a robust mold. The following items are typically required for the design model to create a
robust mold and part:

• Draft - Facilitates the removal of the part from the mold.

• Uniform thickness - Areas of a part that are thicker than others, which can result in sink zones or
warping when cooling occurs.
• Ribs - Adds strength and rigidity to the molded part.
Guidelines for Proper Design Model Preparation
The following are some guidelines for proper preparation of a design model for molding.

• Try to create models that are of uniform thickness, to prevent sink zones or warping in the resulting
molded part.
• Create ribs that are approximately half the model's wall thickness to prevent sink. Apply draft to the
rib walls if they are "vertical" faces. Vertical faces are those that are vertical with respect to how the
mold opens.
• Apply draft in the proper direction at least 0.5 degrees on all "vertical" faces. Draft has been applied
to all faces that are vertical with respect to how the mold opens.
• When creating Draft features in Pro/ENGINEER, either reorder them to be created before any related
rounds or insert them before the rounds. This practice results in a more robust Pro/ENGINEER model.
Creating Rib Features
Ribs are typically used to strengthen parts. A rib feature is similar to an extruded protrusion, except that t
requires an open section sketch. The rib also conforms of existing planar or cylindrical geometry when · i :S
extruded. After you select an open section sketch and set a thickness, Pro/ENGINEER automatically crea�
the rib feature by merging it with your model. The system can add material above or below the ske:cr c:--c
the thickness can be applied on either side or be symmetric about the sketch. The Rib tool enao 5 ....... =

create rib features faster than it would be for you to create and sketch a protrusion.

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The following task explains how to create rib:

1. Open Rib_Feature.prt.
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2. Start the Rib Tool i�
/ from the Feature toolbar. Select RIB_SKETCH- 1 . Specify the width as 7 5.

Fig 2.1: Rib Feature with neutral option

3. Click Complete Feature _.,

4. Start the Rib Tool rb/ . Select RIB_SKETCH-2. Specify the width as 25. The rib is centered about the

sketch.

Fig 2.2: Rib Feature with Neutral

5. Click Change Thickness Option X . The rib moves to the left of the sketch as shown below.

Fig 2.3: Rib Feature Created left of sketch

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6. Click Complete Feature �
/..
7. Start the Rib Tool � . Select RIB_SKETCH-3. Specify the width as 10mm.

Fig 2.4: Rib Feature above from sketch

8. Click the yellow arrow in the graphics window. The rib is now below the sketch as shown.

Fig 2.5: Rib Feature Flipped to below sketch

9. Click Complete Feature

This completes the task.

Creating Draft Features

You can use draft features as finishing features in molded and cast parts or anywhere sloped or angled
surfaces needed to be created. You can define several types of draft features by selecting different
combinations of curves, edges, surfaces and planes for the draft surfaces, draft hinges, pull direction and
split plane (optional). Drafts can add or remove material from a model.

A basic draft feature consists of the following four items:

Draft surfaces - These are the surfaces that are to be drafted. You can select a single surface, multiple
individual surfaces or loop surfaces as the draft surfaces.

Draft hinge - Determines the location on the model that remains the same size after the draft is created.

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The draft surfaces pivot about their intersection with this plane. The� nttd not have to be a physical
intersection. Rather, the intersection can be extrapolated. You can select a datum plane, solid model
surface, curve chain or surface quilt as the draft hinge.

Pull direction - Direction that is used to measure the draft angle. The pull direction is also called the
reference plane. By default, the pull direction is the same as the draft hinge. The direction reference is
used to define the draft angle direction and the draft angle is measured normal to this reference. You can
select a datum plane, planar model surface, linear reference such as an edge or two points, or a coordinate
system axis. The mold opening or pull direction is usually normal to this plane.

Draft angle - Values range from -30 degrees to +30 degrees. When you specify the draft angle, you can
reverse the direction by which the material is added or removed by entering a negative value or by clicking

the Reverse Angle icon X in the dashboard or by right-clicking on the angle drag handle and selecting
Flip Angle.

The following task explains how to create a Draft:

Draft Cylinder surface

1. Open Draft.prt.

2. Start the Draft Tool � from the Feature toolbar. I n the dashboard, select the References tab. Select
the Cylinder surface, to draft it. Click in the Draft hinges collector and select the top cylinder surface.
Edit the draft angle to 10.

Fig 2.6: Draft Cylindrical surface

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3. Click Complete Feature

Draft surfaces

4. Open Draft.prt.

5. Start the Draft Tool 1I> . Select the References tab. In Draft surface Press CTRL and select the four
vertical surfaces, to draft them. Select the top surface of the main protrusion for draft hinge. Edit the
draft angle to -1o.

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Fig 2.7: Draft Surfaces

6. Click Complete Feature 1-itl' .

This completes the task.

Creating Basic Split Drafts

Split draft enables you to apply different draft angles to different portions of a surface.

Split options include:

• No split
• Split by split object
Select a plane:

• Split by Split Object - Splits the draft using a specified datum plane or surface.
• Split by Draft Hinge - Splits the draft using the specified draft hinge.
Side options:

• Independently
• Dependently
• First/Second side only

Fig 2.8: Drafting First Side Only

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Fig 2.9: Drafting Sides Dependently Fig 2.10: Drafting Sides Independently

The following task explains how to create a split draft:

1. Open Draft_Split.prt.
2. Right -click and click Edit the definition on Draft 1 in the Model Tree.
3. In the dashboard, select the Split tab. Select the Split option to Split by draft hinge. Select Split Side
option Draft first side only.

Fig 2. l l : Drafting First Side

4. Click Complete Feature � _

5. Right -click and click Edit the definition on Draft 2 in the Model Tree. Select the Split option to Split
by draft hinge. Select Split Side option as Draft sides independently.

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Fig 2.12: Drafting Sides Independently

6. Right -click and click Edit the definition on Draft 3 in the Model Tree. Select the Split option to Split
by draft hinge. Select Split Side option as Draft sides dependently.

Fig 2.13: Drafting Sides dependently

7. Click Complete Feature � .

This completes the task.

Analyzing Draft Hinges and Pull Direction

By default, the pull direction is the same as the draft hinge. However, yoCJ can select different references
for the draft hinge and pull direction.

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The following task explains Analyzing Draft Hinges and Pu Oirecfon =>..ocec ...re:

1. Open draft_pull-hinge_dir.prt

2. Click the Draft Tool j) from the Feature toolbar. Select the coo s.r.::faa::s o" ine small rectangle
from draft surface as shown.

Fig 2.14: Draft Surface

3. Press SHIFT and select the top edge of the small rectangle. Release SHIFT and notice that the loop
surfaces will be selected as shown.

Fig 2. 15: loop surfact

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4. Select the large. angled surface on which the small rectangle lies for draft hinge. Specify the draft

�00
angle inwards as 1 0 as shown below.

Fig 2.16: Draft Hinge Surface

(jB
5. Click Named View List " and select FRONT.

Fig 2.17: Drafted preview

6. In the dashboard. select the References tab.

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7. Notice the Draft surface, Draft hinge and Pull direction. � OrZt - Pull direction are the
same surface.

Draft swfaces
I OelaiL)
I
LoopSurfaces

rmarMlllllMI, [ .].
Draft h
Details

Pull direction
I Surf:F6(EXTRUDE 1) I[ Fip
l

References Split Angles Options

Fig 2.18: Draft References tab

8. Select Top plane as Pull Direction. Notice the difference in draft as shown.

Fig 2.19: Pulling direction.

9. In the dashboard, click Reverse Pull Direction 1/::!J.

Fig 2.20: Pulling direction changed

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10. Make Draft hinge and Pull direction as same surface. Click Complete Feature � .

Fig 2.21: Drafted part

This completes the task.

Creating Drafts Split at Sketch
You can use a sketch to define custom split lines. You can specify a sketch to be used as the split object.
This enables you to create custom split lines. When you select an existing sketch as the split object, it
becomes linked. However, you can unlink the sketch if desired. You can also define a new sketch. If the
sketch does not lie on the draft surface, Pro/ENGINEER projects it onto the draft surface in the direction
normal to the sketching plane.
•
Sketch becomes linked.
• Sketch can be unlinked.
• A new sketch can be defined.
• Sketch need not lie on draft surface.

Fig 2.22: Draft Splitting Sketch Fig 2.23: Draft Split at Sketch

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Creating Drafts Split at Sketch:

1. Open Draft_Split_Sketch.prt.

2. Click the Draft Tool � from the Feature toolbar. Select the suraces for draft surface and hinge
surface as shown below.

Fig 2.24: Draft Surfatt and hinge

3. In the dashboard, select the Split tab. Se1e<:t Split by split object as the Split option. Select Sketch in
Split object. Select Draft second side only as the Side option.

Fig 2.25: Draft Splitting Sketch

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4. Click Complete Feature

Fig 2.26: Draft Split at Sketch

This completes the task.

Creating Drafts Split at Curve
You can create a draft that splits at a "waistline" curve.

Fig 2.27: Curve for split Fig 2.28: Draft Split at Curve

Creating Drafts Split at Surface

You can create a draft that splits at a "waistline" surface.

Fig 2.29: Surface to split draft Fig 2.30: Draft Split at Surface

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Design Model Analysis

Pro/ENGINEER enables you to analyze the design model for key elements such as proper draft and thickness
before creating the mold model. These tools help you ensure that the design model is acceptable to begin
mold creation.

Analyzing Design Models

You can perform analyses on design models before creating the mold model. Analysis tools enable you
to ensure that the design model is acceptable for mold creation. You can perform the following types of
analyses on design models:

• Draft check
• Thickness check

Performing a Draft Check

You can perform draft checking on a design model by first switching to the Mold application and then
selecting the Mold Analysis option from the Analysis drop-down menu. You can use draft checking to
determine if the design model has the correct surfaces drafted and suitable draft angles in order to facilitate
the mold opening process as well as the removal of the molding component.

You must specify the following references to perform a draft check:

Surface - Specifies the surfaces for which the draft analysis is to be run. You can filter by Part, Surface,
Quilt or All Surfaces using the drop-down list and specify the proper reference.

Pull Direction - Specifies the pull direction to be used for the draft analysis. Usually the pull direction
is the direction in which the mold opens. You can filter the pull direction reference by Plane, Coordinate
System or Curve, Edge or Axis and specify the proper reference. You can also flip the pull direction to the
opposite side of the reference.

You must also specify the following options:

One direction/Both d i rections - Enables you to specify whether the draft analysis is run on one or both
sides of the direction reference.

Draft angle - Enables you to specify the desired draft angle to check for.

Pro/ENGINEER checks the angle between the planes that are normal to the surfaces of the design model
and the pull direction. For a specified draft angle, if the draft check is based on one side, then surfaces with
a higher draft angle appear in magenta in the pull direction. Surfaces between zero degrees of draft up to
the specified draft angle appear in yellow and surfaces with negative draft appear in blue.

For a specified draft angle, if the draft check is based on both sides, then surfaces with a higher draft angle
still appear in magenta in the pull direction. However, surfaces with positive and negative draft up to the
specified draft angle appear in yellow and surfaces with negative draft greater than the negative of the
specified draft angle appear in blue.

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Using the Draft Ana lysis Option

You ca n a l so use the Draft Analysis option to determ i n e if a model is suita b l e for a m o l d or cast i n g
operatio n . Li ke t h e d raft ch eck, yo u m u st sel ect su rfa ces, specify a d i rectio n refere nce, specify one or
both s i d es and a d raft a n g le. The system then p rod u ces a co l o r plot of the d raft a n g l es. Based o n the
h ig h l ig hting, you ca n identify a reas that d o not have sufficient d raft a n g l es. The fo l l o w i n g opti o n s a re
ava i l a b l e for adjusti n g the p l o t :

• Sample - E n a b l es you to specify how the p l ot resol ution is ca lcu lated. O ptions i n c l u d e Qu a l ity,
N u m be r a n d Step.
• Qua l ity - Adjusts the q u a l ity of the p lot.

W h e n you perform a Draft Analysis, you can obta i n the Color p l ot of draft angles on the m o d e l . There a re
th ree d i ffe rent styles of co lor p lot. They a re :

• Rainbow - Displays a p l ot with n u m e rous co l o rs.

• Gradient - Provides a th ree co l o r d is p l ay i n the g ra p h i cs w i n d ow. Sufficient positive d raft a n g les
a p pear in red , sufficient negative d raft a n g l es a p pea r in blue and i n suffi cient a ng l es a p pear in wh ite.
• Two-color - Provides a two-co l o r display in the g ra p h i cs w i n d ow.

Fo r R a i n bow a n d Grad ient p l ots, you ca n specify w heth er the co l o r sca l e is Conti n u o u s o r specify the
desi red q u a ntity of col o rs that a ppea r.

The fo l l o w i n g task exp l a i ns how to perform a d raft c h ec k a n d d raft a n a lysis on a part mod e l :

1. O pe n Draft_Check.prt. Click App l i cations > Mold/Casting from the m a i n m e n u .

2. C l i ck Ana lysis > Mold Ana lysis from the main menu.

3. I n t h e Mold Analysis d i a log box, sel ect Draft Check as the Type. C l i ck Select Part a n d select

the pa rt m o d e l . C l i c k OK from the Select d i a log box. Click Select Plane m a n d sel ect the d a t u m
plane TOP, from the M o d e l Tree.

Fig 2 .3 1 : Mold model sel ected for ana lysis

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4. Select One Direction as the Angle option if necessary.

5. Edit the Draftangle to 2 and click Compute.
6. Rotate the model, so that you can see the pegs underneath.
7. Notice that there is positive draft on the pegs and it needs to � n�ative.

Fig 2.32: Mold model color while analyzing

8. Click Flip Direction and click Compute.

9. Notice that the colors have been reversed. Click Flip Direction again.
10. Click Close from the MoldAnalysis dialog box.

Fig 2.33: Mold model color while analyzing

1 1 . Right-click Draft 3 and select Edit.

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1 2 . Ed it the Draft angle to -3 and click Regenerate g:

Fig 2.34: Mold model Regenerated

13. Click Analysis > Mold Analysis.

14. Repeat the same draft check analysis and notice that the pegs are now drafted the correct way for
molding.

Fig 2.35: Mold model analyzing after regeneration

15. In the Mold Analysis dialog box, edit the Angle option to Both Directions and click Compute.
16. Notice that there is no change in the plot. Edit the Draft angle to 4 and click Compute. Notice that
the pegs are now yellow in color. Click Close.

Fig 2.36: Mold model analyzing after changing draft angle

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Running Draft Analysis on the part model

17. Click Analysis > Geometry > Draft from the main menu.
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18. Select draft-check.prt from the Model Tree. Right dick in the geometry area and select Direction
Collector.

19. Select datum plane TOP, from the Model Tree. Click Both Directions I!) . Edit the Draft angle to 3.
20. Notice that the plot looks similar to the draft check.

Fig 2.37: Running draft analysis

21. In the Draft dialog box, edit the Draft angle to 7 and press ENTER.
22. Notice all the colors on the part model and compare them to those displayed in the Color Scale dialog
box.
23. Notice that the angled surfaces on the top of the model actually are two different draft angles.

Fig 2.38: Running draft analysis

24. Click Complete Analysis �-

This completes the task.

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Performing a Thickness Check
You can perform a thickness check on a part model to check for maximum or minimum thickness at
specified locations.

Fig 2.39: Displaying Thickness CS through Selected Planes Fig 2.40: Displaying Thickness CS through Slices

You can also perform a thickness check within Mold mode by clicking Analysis > Thickness Check from
the main menu.

Once the part is specified, the thickness check is similar to that of the model analysis thickness check,
although the interface is slightly different. You can either select one or more planes to measure the
thickness or you can have the system create slices based on selected references. The system can check for
both maximum and minimum thickness based on the specified thickness value you provide and the results
appear in the Model Analysis dialog box similar to those of the Thickness dialog box.

You can have the system perform the following two thickness checks at each specified reference:

• Max - Checks for maximum thickness. The system performs a maximum thickness check based on
the value that you specify.
• Min - Checks for minimum thickness. The system performs a minimum thickness check based on the
value that you specify.

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Mold Mode

You can start the mold design process by creating a mold model. You need to assemble and orient the
reference model that represents the design model being molded. You can also pattern or assemble the
reference part multiple times to create multi-cavity molds.

- -- -=- - � """"
-- - -- � --
-·
""'"" .- - -- - - -
-
-� -- = - -- - ! -

Fig 2.41: GUI of Molding

Fig 2.42: Planes and pull direction in Mold module

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Creating new Mold Models
A mold model is the model you work on while in Mold Cavity Design mode or Mold mode. The mold model,
which has a file extension of •.mfg, contains an assembly •.asm that is created automatically and usually
consists of the following:
• A reference model.
• One or more work pieces that represent the overall size of the cavity inserts.
• Several mold components that represent cavity inserts.
• One molding component that represents the product of the molding process.
You can create new mold models within Pro/ENGINEER either by using File > New or by clicking New icon

g__. You can type the name of the mold and decide whether to use a default template or a template at
all. Unless you select the Empty template, the new mold displays in the graphics window with some sort
of default datum features.

Fig 2.43 New window

Using Templates
You should create new mold models using a template. Using a template, to create a new mold is beneficial
because it means that regardless of who created it, the mold contains the same consistent set of information,
including:
• Datums - Most templates contain a set of default datum planes and a default coordinate system, all
named appropriately.
• Default Pull Direction - The d irection in which the mold opens.
• Layers - When every mold, part and assembly contains the same layers, it is easier to manage both
the layers and items on the layer.
• Units - Most companies have a company standard for units in their molds. Creating every mold with
the same set of units ensures that no mistakes are made.
• Parameters - Every mold can have the same standard Meta data information.
• View Orientations - Having every mold contain the same standard view orientations aids the molding
process.

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Modifying the Default Pull Direction

The default pull direction is visible on the model at all times, as a double set of arrows, as shown in the
below figure. It is used as a default direction for all mold-specific features and analysis depending on
the pull direction. You can change the direction of the default pull direction by clicking Edit > Setup
from the main menu and selecting Pull Direction from the menu manager. The reference that you select
causes the pull direction to become perpendicular to that reference. Keep in mind that if you modify the
default pull direction within a mold model created using a template, you should rename the datum planes
appropriately.
The following task explains how to Create New Mold Models:
Creating New Mold Model using default template
1. Click File > New from the main menu.
2. Select Manufacturing as the Type and Mold Cavity as the Sub-type. Edit the Nome to NEW_MOLD.
Notice that the Use default template is selected. Click OK.
3. Notice that an assembly of the same name as the mold cavity is created in the Model Tree. Explore
the default datum features created in the graphics window and Model Tree. Notice the PULL_
DIRECTION.

O
rg MRmll.ASM
-0 MOl.D_ISiHT

E
MAlN_PARTNi_PlN
DMOLD FRONT
* MOLD_DEF_CSVS
· + InsertHerc

Fig 2.44: New mold module Model Tree

Fig 2.45: Planes and pull direction

4. In the Model Tree, click Show > layer Tree. Notice the default layers.
5. Click Show > Model Tree.

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@ l.ayetS
@� Ol_All_DTM_PLN
$-@. Ol_ASM_All_DTM_PLN
@-£:701_ASM_DEF_DTM_PLN
f--c7 0l_PRT_All_DTM_PLN
�Ol_PRT_DEF_DTM_PLN
ffi-'f§J 02_All_AXES
� 02_ASM_All_AXES
i-....c7 02_PRl_ALl_AXES
r:h..a n� t. 1 1 r111�vs:c:

Fig 2.46: Layers

6. Click Edit > Setup from the main menu.

7. Click Units from the menu manager. Notice the units that are set.
8. Click Close.

-
i!i--- -­
'----..,,,.- -c

Fig 2.47: Units window

(jB
9. Click Named View List � . Notice the default view orientations.
10. Select the view orientation FRONT.
1 1 . Notice that the PULL_DIRECTION for the mold points upward from the parting plane.

12. Click Named View list [d�j and select Standard Orientation.

Rg 2.48: Planes and pull direction

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13. Click Edit > setup > Pull Direction from the menu manager.
14. Select datum plane MOLD_FRONT and click OK from the menu manager.

Thi:
An
Om
Fig 2.49: Planes after changing pull direction
pro

Creating New Mold Models using a different template: Tyf

Rel:
15. Click New D from the Main toolbar. The New dialog box opens. Select Manufacturing as the
am
Type and Mold Cavity as the Sub-type. Edit the Name to SELECT_TEMPLATE. Clear the Use default
template in New dialog box and click OK. Abs
(for
16. In the New File Options dialog box, browse the inlbs_mfg_mold template. Click OK.
feat
17. Again, notice the datum features and pull_direction.
add
•

An;
You
•

Fig 2.50: Planes and pull direction

18. Click Edit > Setup. Click Units. Notice the units that are set.
19. Click Close.

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Systems of \.his lhls

Certineter Garn Second {CGS)

Foot POlXld Second (FPS)
I + Set. . ]
.

Inch lbm Second iProiE Default) I New J....

I Copy_. ]
Inch POlXld Second OPS)
Meter Kiogam Second (MKS)
drr!eter IQogram Sec (mmKs) I Edit . l
. .

I Delete ]
n*ieter Newton Second VmiNs)

I Wo,.. ]
Fig 2.51: Units window

This completes the task.

Analyzing Model Accuracy

One of the most important factors affecting the mold design process is model accuracy. Pro/ENGINEER
provides the following types of accuracy settings:

Types of accuracy:
Relative - This type of accuracy is specified as a fraction of the longest diagonal of the bounding box of
a model. The default relative accuracy is 0.0012.
Absolute - This type o f accuracy improves the matching of models o f different sizes o r different accuracies
(for example, imported models created on another system). To avoid potential problems when adding new
features to a model, it is recommended that you set the reference model to absolute accuracy before
adding additional parts to the model. Absolute accuracy is useful when you are doing the following:

• Copying geometry from one mold to another during core operations.

• Designing models for manufacturing and mold design.
• Matching accuracy of imported geometry to its destination model.

Analyzing Model Accuracy

You can match the accuracies of a set of models in one of the two following ways:

• Give them all, the same absolute accuracies.

• Designate the smallest model as the base model and assign its accuracy to the other models.

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Automatically Controlling Accuracy

You can perform the following steps to automatically set the correct accuracy when creating mold
models:
• Set the configuration Tools > Option > enable_absolute_accuracy to Yes. For this course, this
configuration file has already been properly set.
• Create a new mold model. It receives a default (relative) accuracy value.
• Add the first reference model. If a discrepancy exists between the assembly model accuracy and
reference model accuracy, the system issues a warning and prompts you to confirm changing the
assembly model accuracy. If you accept, then Pro/ENGINEER switches the assembly model accuracy
from relative to absolute and sets it to the value corresponding to the accuracy of the reference
model. If you do not accept, the system warns you that there is an accuracy conflict and generates a
text file with a *.ace file extension i n the working directory.
• Create the mold work piece using the automatic work piece creation functionality. The accuracy of the
work piece is automatically set to be the same as the accuracy of the assembly model.
Implications and Guidelines of Changing Accuracy
When you change the accuracy of a model, you are changing the computational accuracy of geometry
calculations. The accuracy of a mold model is relative to the size of the resultant molding component. The
valid range for accuracy is 0.01 to 0.0001 and the default value is 0.001 2. However, the configuration
Tools > Option > accuracy_lower_bound can override·the lower boundary of this range. The specified
values for the lower boundary must be between 0.000001 and 0.000 1 .
I f you increase the accuracy, the regeneration time also increases. Use the default accuracy unless you
need to increase it. In general, you should set the accuracy to a value less than half the ratio of the length
of the smallest edge on the model to the length of the largest diagonal of a box that would contain the
model. Use the default accuracy until you have a reason not to do so.
Situations for Changing Accuracy
The following are the situations that may cause you to change accuracy:
• Placing a small feature on a model.
• Intersecting two models of a different size. For the two models to be compatible, they must have the
same absolute accuracy. To achieve this, estimate each model size and multiply each by its respective
current accuracy. If the results differ, enter a value for the accuracy of the models that yields the
same results for each. You might need to increase the mold accuracy of the larger model by entering
a smaller decimal number. For example, if the size of the smaller model is 100 and the accuracy is .Ol,
then the product of these numbers is 1 . If the size of the larger model is 1000 and the accuracy is .01,
then the product of these numbers is 10. Change the accuracy of the larger model to .001 to yield the
same product.

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The following task explains how to modify the accuracy of models in a mold model:
1. Open mfg_accuracy.mfg. Notice the warning in the message window stating that there is an accuracy
conflict.

&fwembly components have absolute accuracy conflict. See file MFG_ACCURACY.ACC.

Fig 2.52: Message window

2. I I
Click Folder Browser icon l7ei from the Navigator toolbar and click Working Directory. Click in the
Address bar to highlight its contents. Press END, type mfg_accuracy.acc and press ENTER.
3. Review the accuracy conflict report for the manufacturing assembly.
4. Collapse the browser.

• 810M81
I
e n,WF41M�_03/Accuacy/nig_accuacy.acc Y �t

Accuracy Contlict Report Tor Assenmly KTG ACCURJ.CY. _

1. Kodels in the list may have accuracy set to absolute or r
2. When the mode l ' s acc'1racv is relative, an absolute accura
is calculated based on the mode l ' s relative accuracy.
3. The tollowinq list shoe the absolute accuracy value tor
that is actually used in Qeometry calculations •

Generic Bodel N111111e .lbs .Lccuracy Value UDit

KTG .LCCURA.CY. ASll 0 . 007300000 DID
KTG-.LCCUR.LCY-R!'T.PRT 0 . 001607587 DID
ACCURJ.CY_VRK.PRT 0 . 006235133 DID

Fig 2.53: Models accuracy window

5. Select Model Tree CEJ from the Navigator.

6. Click Edit > Setup from the main menu.
7. Click Accuracy > Absolute > Select Model from the menu manager.
8. Double-dick mfg_accuracy_ref.prt from the Open dialog box.
9. Click Yes from the message window, to accept the absolute accuracy of the reference part.
10. Click Yes to continue the full part generation.
1 1 . Click Quit from the menu manager.
12. Notice that the accuracy has been changed to 0.0046 (absolute).

Fig 2.54: Message window changed accuracy

13. Right-dick accuracy_wrk.prt and select Open.

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14. Click Edit > Setup from the main menu.

15. Click Accuracy from the menu manager.
16. Press ESC to return to the Accuracy menu.
17. In the menu manager, click Absolute > Select Model.
1 8. Double-click mfg_accuracy_ref.prt from the Open dialog box.
19. Click Yes from the message window, to accept the absolute accuracy of the reference part.
20. Click Yes to continue the full part generation.
21. Click Quit from the menu manager.
22. Notice that the accuracy has been changed to 0.0046 (absolute).

• Regener:atlon coqileted successf\jy•

• Acaracy has been � to 0.0046 (absokte).

Fig 2.55: Message window indicates updated accuracy

23. Click Close Window [E] to return to mfg_accuracy.mfg.

24. Click Save IS!! from the Main toolbar and click OK to save the manufacturing model.

25. Click File > Erase > Current and then click Select All [jJ and OK to erase the model from
memory.
26. Click Working Directory d" and double-click mfg_accuracy.mfg to open it.
27. Notice that there is no longer an accuracy conflict in the message window. All components in the
mold manufacturing model are set to the same absolute accuracy value.
This completes the task.

Creating the Reference Model

The reference model usually represents the part that is to be molded.

Reference model creation methods:
• Merge by Reference
• Same Model
• Inherited
The first component you typically assemble in the mold model is the reference model. The reference model
usually represents the part that is to be molded. The reference model is needed to imprint corresponding
geometry on mold components. The geometry imprinted into the mold components becomes the Mold
cavity.

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The reference model geometry for a mold model is derived from the corresponding design model geometry.
The design model may not always contain all necessary design elements such as drafts, fillets and shrinkage
that are required for the mold design process. Sometimes the design model contains design elements that
require post-molding machining. These elements should be changed on the reference model to suit the
mold design process.
You can create the reference model by using the following methods:
Merge by Reference - Pro/ENGINEER copies design model geometry into the reference model using
an External Merge feature. Only the geometry, datum planes and layers are copied from the design
model. If a layer with one or more datum planes associated with it exists in a design model, the layer, its
name, display status and the datum planes are copied from the design model to the reference model. Any
changes made to the reference model do not affect the original design model. The default name for the
new reference model created with this method is MOLD_MODEL_NAME_REF.PRT. For example, if the mold
model is CAMERA_MOLD.MFG, the new reference model is CAMERA_MOLD_REF.PRT then any changes
made to the original design model automatically propagate to the reference model.
Same Model - Pro/ENGINEER uses the design model as the reference model. The reference model is the
design model. Therefore, any changes made to this reference model do affect the design model, as you are
actually modifying the original design model. As a result, you cannot rename this reference model when it
is the same model as the original design model.
Inherited - The reference model inherits all geometry and feature information from the design model
using an External Inheritance feature. You can specify the geometry and the feature data that you want to
modify on the inherited reference model without changing the original design model. Inheritance provides
greater freedom to modify the reference model without changing the design model. Any changes made to
the reference model do not affect the design model. Similar to the Merge by Reference method, the default
name for the new reference model created with this method is MOLD_MODEL_NAME_REF.PRT. Again, any
changes made to the original design model automatically propagate to the reference model.
Assembling the Reference Model
Once the reference model is selected, it is automatically assembled into the mold model. If you have
absolute accuracy enabled, the system prompts you to confirm the accuracy change that needs to occur to
properly match the mold model accuracy to the reference model accuracy. The reference model icon that
displays in the model tree is different than that of a conventional part model, regardless of the method
used to create it.
When the reference model is assembled into the mold model, the resulting geometry in the graphics
window looks the same, regardless of the method used to create the reference model. You must expand
the Model Tree to determine the method used.
The following task explains how to Create the reference model in Merge by Reference:

� from the Mold toolbar. Open dialog box

•
1. Open ref-model_merge.mfg. Click Mold Cavity Layout
appears.
2. Double-click button.prt from the Open dialog box.

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3. I n the Create Reference Model d i a l og box, sel ect M erge b y Reference as t h e Reference Model Type.
N otice the Design Model. Edit the Reference Model Name to BUTTON_REF and c l ick OK as shown

below.

·..!. Create Reference Model 0

� Reference Model Type

@ Merge by Reference
0 Same Model

r
0 Inherited

!"-"""" j
I
Design Model
�
1
ame BUTTON

!
1I
N.,. BUTTON_REF

Common Name !

l OK I I Cancel
I
Fig 2.56: Create Reference Model window

4. Click OK in the Layout d ia l og box.

5. Click OK in the Warning dia log box to change the accu racy.

6. Click Done/ Return from the menu mana g e r.

g�
7. Cl ick Regenerate a= .

Fig 2.57: Reference M o l d model

8. Expand BUTTON_REF.PRT in the Model Tree.

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9. Notice that the reference model only contains an external merge feature.
n
'.;J RU-MOOE!._l"ERCZ.ASM
D MOID_RlGff
D MAINJ'AATINGJ'lH

�MOID_PE1'_CSYS
-0 MOIDftOHT

a -Q�ON REF.�jj
flCtemal Mlrve Id 495
1 l + 1nsert Hit•
'- + Insert Here

Fig 2.58: Model Tree merge reference

Create the reference model in Same Model:

Open ref-model_same.mfg. Click Mold Cavity Layout � from the Mold toolbar. Open dialog
1•
10.
appears.
11. Double-click button.prt from the Open dialog box.
12. In the Create Reference Model dialog box, select Same Model as the Reference Mode/Type. Notice the
Reference Model Name and that the field is grayed out. Click OK.
13. Click OK in the layoutdialog box.
14. Click OK in the Warning dialog box.
15. Click Done/Return from the menu manager.
o\.�
16. Click Regenerate g� .

Fig 2.59: Reference Mold model

17. Expand BUITON.PRT in the Model Tree.

18. Notice that the reference model is the original model.

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Create the reference mode\ \n \nherited�

19. Open ref-model_inherited.mfg. Click Mold Cavity Layout � from the Mold tootbar. Open dialog
appears.
20. Double-click button.prt from the Open dialog box.
2 1 . In the Create Reference Model dialog box, select Inherited as the Reference Model Type. Edit the
Reference Model Name to BUTION_REF_I and click OK.
22. Click OK in the Layout dialog box.
23. Click OK in the Warning dialog box.
24. Click Done/Return from the menu manager.
O-t_+
25. Click Regenerate 8== .

Fig 2.60: Reference Mold model

26. Expand BUTION_REF_l.PRT in the Model Tree.

27. Notice that the reference model only contains an External Inheritance feature.

g RfH«lOEl..,J>ffJUTtl).ASM
1-·0 MOl.OJUQil
0 MAIHJ'AATlNG.}'Ut

�lolOU>.JlO'_CSYS
OMOU>..fllONT

9 0 RU.+!000. ..PK .JlfJ'.Pl!T

��NIw.rt.... ld �9S(MTONJIRT)
RntD

L+ "-t1tore
..... .. '11"4<tllol1'

fi9 'l.6': Mooe\ "'itcc

This completes the task.

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Redefining the Reference Model

You can redefine the reference model either by clicking Mold Cavity Layout !�
from the Mold toolbar
and then by clicking Redefine or by clicking Mold Model > Locate Refpart > Redefine from the menu
manager. You can redefine the following items related to the reference model:
Reference model orientation - You can adjust the reference model origin and orientation within the mold
model. You can do this by either adjusting the reference model coordinate system or the mold model's
coordinate system.
Mold cavity layout - You can adjust the quantity and layout of the mold cavities created within the mold
model.
Mold cavity layout orientation - You can adjust the orientation of the mold cavities created within the
mold model.
Note that you cannot change the current reference model to a different reference model.
Switching Reference Model Methods
If you have created the reference model using the Same Model method, you cannot redefine the method
to switch it to Merge by Reference or Inherited. Conversely, if you have created the reference model using
either Merge by Reference or Inherited, you cannot redefine the method to same Model. In either of these
cases you must delete the reference model from the mold model and recreate it.
You can switch the reference model creation method back and forth between Merge by Reference and
Inheritance; however you can do this by editing the definition of the External Merge or External Inheritance
feature within the reference model, depending on the type of creation method used. You can then toggle
the inheritance ON or OFF in the dashboard. Keep in mind that by switching back and forth you will
lose any geometry that was varied in the inheritance feature and the resulting geometry may change,
potentially causing other geometry to fail.
Analyzing Reference Model Orientation
You can modify the orientation of the reference model in the mold model. When you select the reference
model to be added to the mold model, the system selects a coordinate system from the reference model
and assembles it to a coordinate system from the mold model.
Modifying the Reference Model Orientation
You can modify the reference model orientation within the mold model either by specifying a different
mold layout coordinate system or by specifying a different reference model coordinate system.

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There are two different methods that you can use to specify a different coordinate system in the reference
model:
•
Standard - Enables you to select a different, existing, coordinate system in the reference model.
A separate window opens that contains the reference model, enabling you to select the coordinate
system.
• Dynamic - A separate window opens, that contains the reference model. However, a new coordinate
system called REF_ORIGIN is created in the reference model and you can dynamically reorient this
coordinate system so that it will line up properly with the mold layout coordinate system.
You can dynamically adjust the coordinate system orientation in the reference model window and the
parting plane also adjusts dynamically. The following options are available for adjusting the REF_ORIGIN
coordinate system orientation:
Rotate - Enables you to rotate the REF_ORIGIN coordinate system about the X, Y and Z axes, either by
typing a value or by dragging a slider.
Translate - Enables you to translate the REF_ORIGIN coordinate system in the X, Y and Z directions, either
by typing a value or by dragging a slider.
Move To Point - Enables you to move the REF_ORIGIN coordinate system origin to a specified point in
the reference model. There are two options available:
• Selection - Enables you to select a vertex, datum point or other coordinate system as the new
coordinate system origin.
• Model Center - Moves the coordinate system origin to the model center.
Align Axis - Enables you to align the X, Y or Z axes of the REF_ORIGIN coordinate system to a specified
datum plane, curve, edge, axis or other coordinate system.
The following task explains how to Reorient the reference model using dynamic methods:
1. Open ref-orient.mfg. The model is not in proper orientation with respect to the pull_direction.

Fig 2.62: Mold model without proper pulling direction

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2. Click Mold Cavity Layou t � from the Mold toolbar.

3. Click Redefine from the menu manager.

4. Click Reference Model Origin from the Layout dialog box.

5. Select Dynamic from the menu manager.

6. Notice the Parting Plane and the positive Z-direction.

oy

Fig 2.63: Mold model for orient

7. In the RefModel Orientation dialog box, verify that Rotate is specified for the X Axis. Drag the slider
to the right until, about 90 and then edit the Value to 90 and press ENTER. Notice the Parting Plane
and the positive Z-direction. Click OK.

Fig 2.64: Oriented axis

8. Click Preview.

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9. Notice that the orientation is now correct for the pull_direction. n:;, tna< the main_parting_pln is
on the top of the model.

Fig 2.65: Mold model with Changed pul direction

10. Click Reference Model Origin from the Loyoutdialog box.

11. Select Dynamic from the menu manager.

12. In the Ref Model Orientation dialog box, click Translate and select the Z Axis. Drag the slider all the
way to the left so the value is -7 00 Click OK.
. .

Fig 2.66: Mold model for dynamic move

13. Click Preview from the Layout dialog box.

1 4. Notice that the main_parting_pln is now in the bottom.

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is 15. Click OK from the Layoutdialog box and Done/Return from the menu manager.

MAIN PARTING PL

Fig 2.67: Mold model Reoriented

Reorient the reference model using standard orientation methods:

16. In the Model Tree, expand REF-MODEL.PRT.
17. Right-click STD_CSYS and select Resume.

�
the
18. Click Mold Cavity Layout and click Redefine from the menu manager.
19. Click Reference Model Origin W from the Layout dialog box.
20. Verify that the coordinate system type is Standard in the menu manager.
21. Select coordinate system STD_CSYS.
22. Click OK from the Layout dialog box.
23. Click Done/Return from the menu manager.

Fig 2.68: Mold model indicates STD_CSYS Fig 2.69: Mold model Oriented to STO_CSYS

-,.·s completes the task.

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Analyzing Mold Cavity Layout

You can create a mold model that contains multiple cavities. The following mold cavity layout options are
available:

• Single
•
Rectangular
• Circular
•
Variable

PULL DIRECTION

Fig 2. 70: Single cavity

Fig 2.71: Rectangle cavity

Fig 2.72: Circular cavity

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Single - Places a single cavity or single instance, of the reference model in the mold model.

Rectangular - Places the reference model in a rectangular layout in the mold model. The following
> are
options are available for the Rectangular layout:

•
Cavities - Specifies the number of cavities or number of pattern instances of the reference model in
the X and Y directions. You can either edit the number or use the up and down arrows to increase or
decrease the number of cavities in each direction.
• Increment - Specifies the distance between origins of reference models in the X and Y directions.
• The X and Y directions are determined by the mold model coordinate system's X and Y axes.
Circular - Places the reference model in a circular layout in the mold model. The following options are
available for the Circular layout:

• Cavities - Specifies the number of cavities or number of pattern instances of the reference model in
the mold model.
• Radius - Specifies the radius value around which the cavities are placed.
• Start Angle - Specifies the angular distance in degrees about the mold model's Z-axis that the first
reference model's origin is placed. You can specify a negative value.
• Increment - Specifies the angular distance between cavities in degrees.
Variable - Enables you to place the reference model according to a user-defined pattern table.

The following task explains how to Analyze mold cavity layout in a mold model:

1. Open cavity-layoutmfg.

MAI N_PARTING_PLN

Rg 2.73: Mold model

2. Click Mold Cavity Layout � from the Mold toolbar.

3. Click Redefine from the menu manager.
Notice that the current layout specified is Single.

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5. Select Rectangular as the layout.

•
Edit the X Covityto 3.
• Edit the YCavity to 3 .
• Edit the X Increment to 30.
•
Edit the Y Increment to 30.
6. Click Preview.

MAIN

Fig 2.74: R�fincd to Rectangle cavity

7. In the Model Tree, expand the Pattern feature.

8. Notice that there are 9 pattern members total.

9. These pattern members correspond with the number of cavities in the mold model.

e D l>attom (CAVITY·l.AYOUT-11!1'R1)

$ QCAVITY·l.AYO\IT·ID.PRT
Ill 0 CAVITY·l.AYO\IT·R£f Piil

iii �CAVITY•l.AYO\IT·IW'.PRT
Ill 0CA'l!TY·l.AYO\IT·REf.PRT
Ill 0CA'l!TY·LAVOUT·RIF.Pl\T
Ill 0CA'l!TY·LAYOUT·Mf.PRT
Ill 0CAVTTY·LAYOUT·REf.PRT
Ill OCA'l!TY·lAYOUT·W.PRT
W OCAVITY·l.AYOUT·W.PttT
· -Ht<•

Fig 2.75: Model tree for rectangle cavity

10. I n the layout dialog box. edit the X and Y Increments to SO.

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1 1 . Click Preview.

MAIN

Fig 2.76: Rectangle cavity preview

12. In the Layout dialog box, edit the number of Y Cavities to 2.

13. Click Preview.

Fig 2.77: Rectangle cavity

14. In theLayout dialog box, select Circular as the Layout. Edit the number of Cavities to 4.Edit the Radius
to 40 and click Preview.

Fig 2.78: Circular cavity with total angle

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15. Edit the Start Angle back to o.

16. Edit the Increment to 60 and click OK from the Layout dialog box.
17. Click Done/Return from the menu manager.

PULL DIRECTION

Fig 2.79: Circular cavity with start angle and end angle

This completes the task.

Analyzing Variable Mold Cavity Layout

You can create unique cavity layouts using the Variable layout option. You can also convert an existing
layout to Variable.

The following orientation options are available for each pattern instance in the Variable table:

Reference Rotationlx 'i'l Rotates the reference model (pattern instance) about its origin.
-

X-Translation La if - Translates the reference model along its positive or negative X-axis.

Y-Translation ls •f - Translates the reference model along its positive or negative Y-axis.

Layout Rotation la •1 - Rotates reference model about the mold layout origin.

Of these four options, the Y-Translation and Layout Rotation options are not always available, depending
upon which layout was converted to Variable. The Layout Rotation option is only available for a layout
converted from Circular, as shown in the below figure. The Y-Translation option is only available for a
layout converted from Single or Rectangular.

Additional Variable cavity layout options include the following:

Highlight - When this check box is selected, any pattern instance selected in the Variable table highlights
in the graphics window.

Add - Enables you to add a new pattern instance to the layout. The new pattern instance member is
inserted immediately following the pattern instance that is selected when the Add button is clicked.

Remove - Enables you to remove an existing pattern instance from the layout. To remove a pattern
instance, select it in the Variable table and click Remove.

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The following task explains how to Analyze Variable Mold Cavity layout:

1. Open variable-layout.mfg. Click Mold Cavity Layout � from the Mold toolbar and click Redefine
from the menu manager.
2. Notice that the layout is a Single cavity.

Fig 2.80: Mold model in Single cavity

3. I n the Layout dialog box select Variable as the Layout. Notice the new Variable table. Select the
Highlight check box. Select VARIABLE-LAYOUT_REF and notice that it highlights in the graphics
window.

Fig 2.81: Highlighted Mold model for Variable cavity

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Ls'i\ •
'
to 90:. =.-- J.-T"Drzslotion t-1
-
4. In the Variable table, edit the Reference Rotation to-
40 and edit the Y-Tronslation L, •f to -40 and cliett �..

PULL
----r'\ _oEF_cs s
01REcr16tJM0Lo I

Fig 2.82: Rotated cavity

5. In the Layout dialog box, click Add. Edit the Reference Rotation L,$ to -90. Edit the X-Translotion
Ls • to -40. Edit the Y-Tronslotion Li •f to 40 and click Preview.

Fig 2.83: Translated cavity

6. In the Variable table, select the second pattern instance and click Add. Edit the Reference Rotation
L,./F to -90.Edit the X-Translotion L if to SO.Edit the Y-Tronslotion L •f to -40 and click
Preview.

Fig 2.84: Rotated and translated Variable cavity

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to- 7. In the Variable table, select the third pattern instance and click Add. Edit the Reference Rotation
"" Ii' to 90. Edit the X-Translation Li S to -50. Edit the Y-Translation L, .t' to -40 and click
Preview.

Fig 2.85: Final Variable cavity layout

Modify the variable cavity layout to a different layout

8. In the Layout dialog box, select Circular as the Layout, edit the Radius to 60 and click Preview.
9. Select Variable as the Layout
10. I n the Variable table, select the first pattern instance and edit the Reference Rotation L ii' to -90,
the X-Translotion • to 60 and the Layout Rotation L, •1 to o.

11. Edit the remaining pattern instance orientation values, as shown in the table below.

VARIABLE·LO.YO
VAAIABLE·lAYO
VARIABLE·LO.YO
VARIABLE·LO.YO

<

Fig 2.86: Variable cavity window

12. Click OK from the Layoutdialog box.

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13. Click Done/Return from the menu manager.

...
PULL DIRECTION
T_cSYS_

Fig 2.87: Variable Cavity converted to circular cavity

This completes the task.

Analyzing Mold Cavity Layout Orientation

You can adjust the orientation of the cavities in a multi-cavity layout. Examples of reasons why cavity
adjustment may be necessary include the following:
• More optimum layout for sprue and runner placement is required.
• More uniform cooling of parts is needed.
• Manufacturing feasibility of the mold design layout.
Consider each of the mold cavity layouts and their respective options for orientation.
Modifying layout Orientation in a Single Cavity
Because there is only a single cavity, no further orientation adjustments are available. The Orientation
options become grayed out in the Layoutdialog box. Rather, you can adjust the cavity orientation in the
layout by switching coordinate systems or dynamically adjusting the REF_ORIGIN coordinate system.
Modifying layout Orientation in a Rectangular Cavity
The following Orientation options are available for the Rectangular cavity layout:
• Constant - Cavities are arranged to all points in the same direction.
• X-Symmetric - Cavities are mirrored about the mold model's X-axis.
• Y-Symmetric - Cavities are mirrored about the mold model's Y-axis.

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Modifying Layout Orientation in a Circular Cavity

The following Orientation options are available for the Circular cavity layout:

• Constant - Cavities are arranged to all points in the same direction.

• Radial - Cavities are fanned about the mold model's origin.

Fig 2.88: Rectangular Layout, X-Symmetric versus Y-Symmetric Orientation

ion
the

Fig 2.89: Circular Layout, Constant versus Radial Orientation

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The following task explains how to Analyze Mold Cavity layou: O ·e'"tGLor. Procedure:

Open layout-orient.mfg. Click Mold Cavity layout P. from :r.e lfoa mo oar.
••
1.

2. Click Redefine from the menu manager.

3. In the Layout dialog box, notice that the Layout is specified as Rectangu ar. otice that the Orientation
is specified as Constant.

Fig 2.90: Rectangle cavity with constant

4. In the Layout dialog box, edit the Orientation o X-Symmetricandclick Preview. Notice that the cavity
\a'lout is S'lmmetric about the maid rnode.1 s X-axis.

Fig 2.91: Rectangle cavity with X-Symmetric

s. In the Layout dialog box, edit the Orientation to Y-Symmetric. Click Preview.

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6. Notice that the cavity layout is symmetric about the mold model's Y-axis.

Fig 2.92: Rectangle cavity with Y-Symmetric

7. In the Layout dialog box, edit the Layout to Circular. Edit the Orientation to Constant if necessary. Edit
the Radius to 30 and click Preview.
8. Notice that all the cavities face the same constant direction.

ity

Fig 2.93: Circular cavity with constant

9. In the Layout dialog box, edit the Orientation to Radial and click Preview. Notice that the cavity
layout is radial about the mold model's origin.

Fig 2.94: Circular cavity with Radial

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10. In the Layout dialog box, edit the Layout to Single.

11. Notice that all the Orientation options are grayed out Clidc OK.
12. Click Done/Return from the menu manager.
This completes the task.

Lab Session 2 . 1

The aim of this exercise is to create the Shower Head Mold Model. After successfu lly completing this
exercise, you will be able to:
• Create a new mold model.
• Assemble the reference model.
• Modify the mold cavity layout.
In this exercise, you will create a new shower head mold model by assembling a multi-cavity reference
model. You have already analyzed the design model and verified that the model is sufficient for molding.
Shower_Head Model to be molded

Fig 2.95: Shower_Head model

Create a new Shower head mold model

1. Click New _9 from the main toolbar and New dialog box appears. Select Manufacturing > Mold
Cavity. Type shower_head_mold as the Name and click OK.

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Fig 2.96: Default Planes

..

2. Click Mold Cavity Layout .Q. from the Mold toolbar to assemble the reference model.
3. In the Open dialog box, double-click shower_head.prt to open it.
4. In the Create Reference Model dialog box, select Inherited as the Reference Mode/Type and click OK.
5. In the Layout dialog box, click Reference Model Origin W and click Dynamic from the menu
manager.
6. In the Ref Model Orientation dialog box, select Rotate as the Coordinate System Move option and
select Y as the Axis. Type - 1 80 as the Value and click OK.

Mold
Fig 2.97: Mold model for orient

7. In the Layout dialog box, select Rectangular as the Layout. Edit the Number of Cavities in the Xand Y
directions to 2, if necessary. Edit the X Increment to 1 20. Edit the Y Increment to 2 50.Click Preview.

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Fig 2.98: Rectangle layout

8. I n the layout dialog box, edit the Orientation to X-Symmetric. Edit the Y Increment to 1 50. Click
OK.
9. Click OK in the Warning dialog box to accept the accuracy change.
10. Click Done/Return from the menu manager.

11. Click Plane Display Iq] to di sable their display.

Fig 2.99: Rectangle layout with X-Symmetric

12. Click Save IE! from the Main toolbar and click OK to save the model.

13. Click File > Erase > Current and then click Select All [j] and OK to erase the model from
memory.
This completes the exercise .

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0 Reclassifying Mold Model Components

0 Mold Volume Creation

0 Creating Sliders

0 Reference Part Cutout

0 Lifter Mold Volumes Sketching Insert Mold Volumes

0 Parting Line and Parting Surface Creation

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3. Preparing Mold Models
Shrinkage �

You can apply Shrinkage to accommodate the contraction that occurs in the reference model,during
cooling and also ensure that the final mold model matches the original design model.
When a molded part is removed from a mold, it tends to shrink in size as it cools down to room temperature.
The amount of shrinkage that occurs i n a molding is highly dependent on part geometry, mold configuration
and processing conditions. Because the mold components are designed from the reference model, you
must consider the shrinkage of the material i n the reference model before you proceed with the rest of the
mold design process. This typically means that, you can proportionally increase dimensions of the reference
model so that the mold components created are of the pre-shrunk molding size.

Understanding Shrinkage

You can apply Shrinkage to the reference model in Mold mode. You can also apply shrinkage to the design
model or reference model in Part mode. Depending on the method of applying shrinkage and the method
used to assemble the reference model, the shrinkage feature may propagate to the design model.
There are two methods to apply Shrinkage:
• Shrinkage by Scale
• Shrinkage by Dimension
Pro/ENGINEER uses the following formulae to calculate Shrinkage:
1 +S- Uses a pre-calculated shrinkage factor that is based on the original geometry of the reference
model.
1/ (1 -S) - Enables you to specify a shrinkage factor that is based upon the final geometry of the reference
model, once the shrinkage is applied.
In the above formulae, S is the shrinkage ratio specified.

Viewing Shrinkage Information

When shrinkage has been applied to a reference model, you can view the information regarding the
shrinkage by clicking Shrinkage > Shrink Info from the menu manager. An information window appears,
providing you with the following details:
• Model name - Specifies the name of the model that shrinkage was applied to.
• Shrinkage method - Specifies whether the model is shrunk by scaling or by dimension.
• Shrinkage formula - Specifies which formula was used to apply the shrinkage to the model.
• Model Dimensions and Shrinkage Value - When shrinkage has been applied by dimensions, these
specify which dimensions the shrinkage was applied to and the shrinkage value applied to each
dimension.
• Shrink coordinate system - Specifies the coordinate system s when shrinkage is applied by scaling.

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• Shrink factors - Specifies the shrink scaling factors useo e.. s:- • ..
.kage s applied by scaling.
Applying Shrinkage by Scale

You can shrink part geometry by scaling it in relation to coord·nace S\'S�erri directions. You can apply
shrinkage by scale to all the three directions uniformly.
• Isotropic
You can apply different shrinkage ratios to each of the three coordinate system d"rections.

• X-Oirection
• Y-Oirection
• Z-Direction

Fig 3.1: Dimension before shrinkage Fig 3.2: Dimensions after shrinkage

Fig 3.3: Shrinkage applied at different ratios

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The Shrinkage by Scale method enables you to shrink the part geometry by scaling it, in relation to a
coordinate system. You can specify different shrinkage ratios for the X, Y and Z-coordinates. If you apply
shrinkage in Mold mode, it applies only to the reference model and does not affect the design model.
ply
Shrinkage by scale is applied by creating a new shrinkage feature. When you apply shrinkage in Mold
mode, the shrinkage feature is created in the reference model, not in the design model, unless the Same
Model option was used when assembling the reference model into the mold model.
To apply Shrinkage by scale, you must specify the following items:
Coordinate System - Specifies the model coordinate system that the shrinkage feature uses as a reference.
The X, Y and Z-directions of the coordinate system determine the X, Y and Z-directions used for the
shrinkage ratio.
Formula - Specifies the formula you want to use to calculate shrinkage.
Shrink Ratio - Specifies the ratio of shrinkage you want to apply.
The following options are available when applying shrinkage by scale:
Isotropic - When enabled, sets the same shrinkage ratio for the X, Y and Z-directions. You can clear this
check box, to specify a different shrinkage ratio for each of the three directions.
Forward References - When enabled, the shrinkage does not create a new geometry, but changes the
existing geometry so that all existing references continue to be a part of the model. You can clear this
check box to have the system create new geometry for the part on which shrinkage is being applied.
Considerations when applying Shrinkage by Scale
When applying Shrinkage by scale in Mold mode, keep the following in mind:
• A negative shrinkage ratio shrinks the dimension, while a positive shrinkage ratio expands it. For
example, a positive 0.02 shrinkage ratio applied with the 1 +S formula, expands all the model dimensions
by 2 percent, while a negative 0.02 shrinkage ratio shrinks all the model dimensions by 2 percent.
• It is never reflected in the design model, unless the design model is the reference model.
• If it is applied to the design model in Part mode, then the shrinkage feature belongs to the design
model, not to the reference model. Shrinkage is accurately reflected by the reference model geometry,
but it cannot be cleared in Mold mode.
• It should be applied prior to the definition of parting surfaces or volumes.
• It affects part geometry (surfaces and edges) and datum features (including curves, axes, planes, and
points).
Shrinkage by Scale
The following task explains how to apply Shrinkage by scale to a reference model:
1. Open shrinkage_scale.mfg.

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2. In the Model Tree, expand reference model shrinkage_scale.prt. Right-click Extrude 1 and select Edit.
Notice the three feature dimensions.

Fig 3.4: Mold model with dimensions

'3. C.\ic.� Sht\nka9e s'i S<:.a\e R from the Mold too\bar. Shrinkage By Scale dialog box appears.

4. I
Select coordinate system PRT_CSYS_DEF. Select 1• sl as the Formula, if necessary. Verify whether the
Isotropic check box is selected.

5. Edit the Shrink Ratio to 0.5. Click Preview Feature I dd' 1l.
6. Notice that the entire model uniformly gets larger.

Fig 3.5: Mold model after applying shrinkage

7. In the Shrinkage By Scale dialog box, clear the Isotropic check box.
• Edit the X Shrink Ratio to 0.25.
• Edit the YShrink Ratio to 0.25.
• Edit the Z Shrink Ratio to 0.75.

..,
8. Click Apply Changes

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Edit. 9. Notice that the model has grown larger along the Z-coordinate system direction than in the other
two directions.

Fig 3.6: Shrinkage more along Z-coordinate

10. Right-click Extrude 1 and select Edit. Notice that even though shrinkage was applied, the original
dimensions remain unchanged.

Fig 3.7: Dimensions remained the same after shrinkage

11. Click Shrinkage > Shrink Info from the menu manager. The Information window appears.
12. Notice the shrinkage information in the Information window and click Close.

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13. Cl ick Done/Return.

del name : SHRl ..ACE_SCALE

del is SHRU,. by scaling

hrink coordinate suste• :

PRT_CSYS_DEF (created in �rt Sllallll9CE_scal£)

hrinkage for.ula is: 1 • S

X factw • 1 .2511
t facter • 1 .2511
z factw • 1.7511

Fig 3.8: Shrinkagt Information Window

14. Edit the definition of the Shrinkage ID. In the Shrinkage By Scale dialog box, select Ii�sI as the
Formula.
..,
15. Click Apply Changes
16. Notice that the resulting geometry is even more distorted.
17. The shrinkage is based on the final geometry, now that shrinkage is applied.

Fig 3.9: Mold modtl afttr shrinkagt applitd

This completes the task.

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Shrinkage by Dimension
You can specify a single shrinkage ratio for all model dimensions or specify unique ratios for individual
model dimensions.
• Dimensions with shrinkage ratios applied, appear in magenta color in the graphics window.
• Select individual feature dimensions to add shrinkage ratios to.
• Select a feature to add shrinkage ratios to all of its dimensions.

r- 10(50.00%)
--1 ___ �

R1(50.00%) -......

Fig 3.10: Shrinkage ratio applied to all dimensions

I
\ 7
7(75.00%)

Fig 3.11: Model before shrinkage applied Fig 3.12: Different shrinkage ratios applied to specific dimensions

The Shrinkage by Dimension method enables you to set up a single shrinkage ratio for all model dimensions
and specify ratios for individual dimensions.
To apply Shrinkage by Dimension, you must specify the following items:
• Formula - Specifies the formula you want to use to calculate shrinkage.
• Dimensions - Specifies which dimensions to add the shrinkage to.
• Shrinkage Ratio - Specifies the ratio of shrinkage you want to apply.

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Within the Shrinkage By Dimension dialog box, a table displays the folloi ·ng columns:
• Dimensions - Displays which dimensions have a shrinkage ratio applied. The dimension symbol and
original value are displayed in the cell.
• Ratio - Displays the shrinkage ratio for each dimension in the table.
• Final value - Displays what the final dimension value will be after the shrinkage ratio has been
applied.
You can specify a shrinkage ratio for All Dimensions, in the model. The shrinkage ratio is in the first row of
the Shrinkage Ratio table. To add additional dimensions to the table, you can use the following methods:

• Insert Selected Dimensions 1'111 - Displays the dimensions for a selected feature, enabling you to
select and apply the desired shrinkage ratio.

• Insert All Dimensions From Feature • I J Enables you to select a feature in the graphics window.
_

All dimensions comprising that feature are automatically added to the table.

• You can also click Add New Row [!] and type the symbol for the dimension. You can see the given
dimension's symbol, by clicking Toggle Dimensions {i�nJ.
The following options are available when applying Shrinkage by Dimension:
• Change Dimensions of Desig·n Part - Determines whether the shrinkage feature is placed in the
design model or not. Depending on the method of reference model creation, this option may be grayed
out. For example, if the reference model was created using the Same Model, this option does nothing,
as the feature is created in the design model. regardless.
Considerations when applying Shrinkage by Dimension
When applying Shrinkage by Dimension, keep the following in mind:
• A negative shrinkage ratio shrinks the dimension, while a positive shrinkage ratio expands it. For
example, a positive 0.02 shrinkage ratio applied with the 1 + S Formula, expands all the model
dimensions by 2 percent, while a negative 0.02 shrinkage ratio shrinks all the model dimensions by 2
percent.
• If the part has had shrinkage applied, dimensions will be displayed in magenta, when viewed in the
design model or a drawing.
• If the part has not had shrinkage applied, dimensions remain displayed in yellow, when viewed in the
design model or a drawing.
• The configuration file> option, shrinkage_value_display, determines how dimensions are displayed
when shrinkage is applied to a model. The possible values of this configuration option are percent_
shrink and final_value. For the procedure, the value for this configuration option is percent_shrink.
•
By default, whenever a part has shrinkage information associated with it, the nominal dimension
values are displayed, followed by the shrinkage value in parentheses. If you set the value of the
configuration file> option > shrinkage_value_display to percent_shrink, shrinkage is represented as

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percentage of the nominal dimension. You can display the final value of the shrunken dimensions by
changing the value of the configuration file > option > shrinkage_value_display to final_value.
The following task explains how to apply Shrinkage by Dimension to a reference model:
1. Open shrinkage_dim.mfg.
2. In the Model Tree, Expand reference model shrinkage_dim.prt. Right-click Extrude 1 and select Edit.
Notice the three feature dimensions.

\ 7

Fig 3.13: Mold model with dimensions

+-11+
3. Click Shrinkage By Dimension O from the Mold toolbar. In the Shrinkage By Dimension dialog box,

verify whether the Formula is II 1• s IJ.

4. Edit the ratio to 0.5 for All Dimensions and click Apply Changes �
5. Notice that the model gets uniformly larger.
For
del
by 2

� the
n the

�yed
cent_
rink.
llSion Fig 3.14: Model applied shrinkage uniformly
If the
ttd as

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6. Click on the background to deselect all geometry.

7. I n the Model Tree, press CTRL and select Extrude 1 and Round 1 .

8. Right-click and select Edit.

increase they have undergone.
9. Notice that the dimensions are in magenta and display the �rttnt

- 10(50cmr.) ---'

.0)0%
R1(50.cmr.)

Fig 3.15: Dimension color changed after shrinkage

� t+ s
ensions and click Apply Change
O . Edit the ratio to -0.5 for
All Dim
10. Click Shrinkage By Dimension

..,
rude 1 and Round 1 . Right­
d to des elec t all geo met ry. Press CTRL and select Ext
11. Click on the backgr oun t decrease
enta and display the percen
select Edit. Not ice tha t the dimensions are i n mag
click and
they have undergone.

d after shrinkage
fig 3.16: Dimension color change

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12. Click Shrinkage By Dimension Q . Edit the ratio to 0.0 for All Dimensions. Click Insert Selected

Dimensions l�J and select Hole 1 .Select the 3rd dimension.

me. 13. Click Insert All Dimensions From Feature I •I and select Extrude 1 .
14. I n the Shrinkage Ratio table, edit the ratio for dimension d6 to 0.5.
• Edit the d7 ratio to 0.75.
• Edit the d2 ratio to 0.1 5.
• Edit the dO ratio to 0.75.

15. Notice the final values for each of the dimensions in the table and click Apply Changes � � J.

1anges

Right­
crease Fig 3.17: Shrinkage with different ratios

16. Click on the background to deselect all geometry. Press CTRL and select Extrude 1 and Hole 1 . Right­
click and select Edit. Notice that the different individual percentage shrinkage value increases.

r- 10(75.00%)

Fig 3.18: Dimension color changed after shrinkage with different ratios

This completes the task.

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•
Workpieces
•
Once you have created the mold model, you can create and a�bk 11'1' workpiece represents
•
the full volume of all the mold components that are needed to � IUA'""""'cted mold model. You can
also apply style states to the workpiece to make them transparmt d model.
Over
To create workpieces, two methods are available:
can c:
• Automatically sped
• Manual work
for a
Creating a Workpiece Automatically
Tran!
Once you assemble the reference model into tM mold modd. yoo typically create and assemble the
posit
workpiece next. The workpiece is a model that rep�nts the full volume of all the mold components
(cavity, core and inserts) that are needed to create the final mold model. The workpiece icon that displays You c
in the model tree is different than that of a conventional part model and the reference model. as it

Cre:
To create a workpiece automatically, you can use the Create Automatic Workpiece 9 option in the
Mold toolbar. You can also click Mold Model > Create > Workpiece > Automatically from the menu You c
manager. The workpiece is automatically assembled to the Mold Origin coordinate system using the Coord •
System assembly constraint and the accuracy is automatically set to match that of the reference model.

To create an automatic workpiece, you must specify the following items:

•
Mold Origin - The Mold Origin is a mold model coordinate system from which the directions are determined
for workpiece creation.

Shape - Determines the shape of the workpiece. The system creates a workpiece with the minimum
Whea
dimensions that the reference model fits in, within the specified shape. The following options are
techr
available:
Revo
• Standard Rectangular - Creates a rectangular-shaped workpiece using Create Rectangular Workpiece
Asse
liJ.
[•J.
If th(
• Standard Round - Creates a round-shaped workpiece using Create Round Workpiece It mu

• Custom - Creates a custom-shaped workpiece using Create Custom Workpiece I•J. If yoi
must
Units - Specifies the system of units for the workpiece. You can select inches or millimeters.
Modi
Offsets - Enables you to specify the offset values that shou Id be added to the dimensions of the workpiece,
You c
based on the mold origin. The offsets depend on the shape of the workpiece that you have selected. You can
inclu1
specify each offset individually or specify all offsets uniformly. The following offset options are available:
Con!
• X direction - Adds material in the positive or negative X direction. This offset is available only for
Standard Rectangular shape and some custom shapes. Keep

• Y direction - Adds material in the positive or negative Y direction. This offset is available only for •

Standard Rectangular shape and some custom shapes.

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• Z direction - Adds material in the positive or negative Z direction.
• Radial - Adds material in the positive radial direction.
ents
• Uniform Offsets - Adds material in the positive and negative X, Y and Z directions and Radial, where
can
applicable.
Overall Dimensions - The overall dimensions get updated when you specify offset values. However, you
can also specify the overall dimensions and the offset values get updated automatically. You can manually
specify the X and Y dimensions for rectangular and custom workpieces and the diameter for rounded
workpieces, to customize the workpiece size. You can manually specify the Z Cavity and Z Core dimensions
for all workpieces to customize the size.
Translate Workpiece - Enables you to specify the translation values for the X and Y directions i n order to
the
position the workpiece around the reference model.
ients
1>lays You can modify the default Workpiece Name. The Workpiece Name is the name of the workpiece component
as it displays in the Model Tree. By default, its name is of the format MOLD-MODEL-NAME_WRK.

Creating a Workpiece Manually

� the
nenu You can create a workpiece manually using either of the following methods:
bord • Create the workpiece within the mold model by clicking Mold Model > Create > Workpiece >
idel. Manual from the menu manager. The Component Create dialog box appears and you must provide the
name of the workpiece component as it displays in the Model Tree.
• Create the workpiece outside the mold model as a conventional part model. When the part model is
1ined
needed as the workpiece i n the mold model, you can assemble it as a component into the mold model
and designate it as the workpiece.
mum
When creating the workpiece manually, you can use any of the conventional part modeling feature
> are
techniques available, when creating a regular part model. For example, you can use Extrude features,
Revolve features, Hole features, Sweep features and Blend features.
piece
Assembling a Manually Created Workpiece
If the workpiece is created in the mold model, it is already designated as the workpiece upon its creation.
It must then be properly assembled into the mold model.
If you create a part model outside of the mold and want to use it as the workpiece in a mold model, you
must assemble it into the mold model and designate it as the workpiece. You can do this by clicking.Mold
Model > Assemble > Workpiece from the menu manager.
1iece, You can assemble the workpiece into the mold model using any of the available assembly constraints
Han including Default, Mate, Align and Insert.
1ble:
Considerations when Creating and Assembling a Workpiece Manually
Keep the following in mind when creating and assembling a workpiece manually:
y for • If you manually create a workpiece and assemble it into the mold model, you need to match the
workpiece accuracy to that of the reference model.

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• Keep the location in mind, where the workpiece wil' be spl L. Yroca crta:e a datum plane or coordinate 9.
system at this location, to aid in the assembly process a\er.
The following task explains how to create workpieces in a mold mooe : 10.

1. Open auto-wrkpiece_rect.mfg.

2. Click Create Automatic Workpiece 3 from the Mo/dtoolbar. Se ec. Coordinate system mold_def_
csys from the Model Tree.
3. In the Automatic Workpiece dialog box, notice the Name of the Workpiece.

J. Automatic Workpiece
•
®
Fie Edit
,_W'Olkpiece Name--
IAUTO·\llRKPIECE_RECT _\llRK
--
I
Reference Mode{s)- --

I
AUTO.\llRKPIECE_RECT_REF 11.
-
�
I

� Mold Origin 12.

� MOLD_DEF_CSYS I
.-----
-

13.
Fig 3.19: Automatic: Workpiece window

4. In the Automatic Workpiece dialog box, click Create Rectangular Workpiece ·�I. if necessary. Verify
that the units are in mm.
5. Notice that there are no Offsets specified.
6. Notice the Overall X, Y and Z dimensions.
7. Click Preview.
8. Notice that the workpiece just barely covers the reference model.

PULL DIRECTION

Fig 3.20: Work piece covered mold component with d'fault dimensions

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9 In the Automatic Workpiece dialog box, edit the Uniform Offsets value to 30. Notice that the X, Y and
Z direction's, +/- offsets all become 30.
10. Notice that the Overall dimension values have also been updated automatically. Click Preview.

PULL DIRECTION

Fig 3.21: Work piece covered mold component with different dimension

1 1 . In the Automatic Workpiece dialog box, type 40 for the - and + offsets in the Y direction. Click
Preview.
12. I n the Automatic Workpiece dialog box, edit the Overall X Dimension to 340 and the Overall Y
Dimension to 1 GO.
13. Notice that the Offset values have been updated. Click OK.

-Offsets
I
Uniform Offsets 30.IXXXXXl
+

x cirection 29.470292
Y cfirection
Z difection
39.995000
30.000000

� ov��oimension.s�����
�
x
340.000000 I
, so.OOOX>O I

9696..675000
Y

+ Z Caviy
·ZCore
Z Total
-
675000
193.350000 j
Fig 3.22: Workpiece Values

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The following task explains how to Create Automatic Round •Of(

:l
'ece:
1. Open auto-wrkpiece_round.mfg.

2. Click Create Automatic Workpiece EJ and select mold_def_csys. In the Automatic Workpiece

dialog box, click Create Round Workpiece [•I

• Edit the Radial Offset to 5.
• Edit the +Z Cavity to 6.
• Edit the -Z Core to 6.
3. Click Preview.

Fig 3.23: Round Workpiece

4. I n the Automatic Workpiece dialog box, drag the Translate Workpiece X direction slider to the right.
Drag the Translate Workpiece Y direction slider to the left and click Preview.
5. In the Automatic Workpiece dialog box, edit the X and Y Translate Workpiece Directions to O and click
OK.

Fig 3.24: Translated Round Workpiece

This completes the task.

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Creating and Assembling a Workpiece Manually
You can create a part model inside or outside the Mold mode and designate it as the workpiece when
assembling it into the mold model.

• Use conventional part modeling techniques.

• Assemble workpiece using conventional assembly constraints.
• The accuracy of a manually created workpiece must be matched to the reference model.

The following task explains how to Assemble Workpieces Manually in mold models:

1. Open manual_wrk.prt. Notice the part model and its datum planes.

TOP

Fig 3.25: Workpiece to assemble

2. Click Close Window � .

3. Open cap.mfg. Click Mold Model > Assemble > Workpiece from the menu manager.

4. In the Open dialog box, double-click manua l_wrk.prt.

Fig 3.26: Workpiece in assemble mode

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5. In the dashboard, select Defa u l t ,.b. from the constraint drop-down list. ·5
·s
6. Click Complete Component � .
7. Notice the component is now of workpiece color. Notice the workpiece symbol in theModel Tree.

8. Click Done/Return in the menu manager.

8

19

Fig 3.27: Assembled Work piece

9. Click Close Window 0

The following task explains how to create workpieces manually in mold models:

10. Open cap_round.mfg. 20

1 1 . Click Mold Model > Create > Workpiece > Manual from the menu manager.

12. I n the Component Create dialog box, type ROUND_WRK as the Name and click OK.
1 3. Accept the default options in the Creation Options dialog box and click OK.
14. In the dashboard, select Default ):1 from the constraint drop-down list and click Complete

Component �

Fig 3.28: Mold component for Work piett

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15. In the Model Tree, right-click ROUND_WRK.PRT and select Activate.

16. Click Insert > Extrude from the main menu.
17. In the graphics window, right-click and select Define Internal Sketch. Select datum plane TOP as the
Sketch Plane and click Sketch.

18. Click Center and Point Circle 0 and sketch a circle, using the origin as the circle center diameter
to 80.

19. Click Done Section v

Fig 3.29: Sketch for Workpiect

20. Press CTRL + D to orient to the Standard Orientation. Edit the depth to 45.
21. In the dashboard, select the Options tab. Select Blind as the Side 2 depth and type 1 5 as the depth.

22. Click Complete Feature .._, .

23. Click Done in the menu manager.

Fig 3.30: Workpiece created manually

This completes the task.

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Reclassifying Mold Model Components 2

You can switch the classification of components within the mold model. Reclassifying mold components is
a great way to switch which component is used as the workpiece. Each of the following component types
can be reclassified to any of the other types:
• Workpiece
• Mold Base Component
• Mold Component
The following are some points to keep in mind when reclassifying mold model components:
• You cannot reclassify the reference model.
• You cannot reclassify a different model to become a reference model.
• The mold model can contain multiple workpieces.
Removing Mold Model Components
You can remove components from the mold model in any one of the following ways: 3.
• Select the component, right-click and select Delete.
• Select the component and press DELETE. 4.
• Select the component and click Edit > Delete > Delete.
When a component is deleted, the following options will be available:
Place Again - Enables you to place the deleted component again in the mold model. You have two options
for placing the component again:
• Automatic - Places the component back in its previous location.
• Manual - Enables you to reassemble the component using different assembly constraints.
Replace - Enables you to replace the deleted component with a different component. You can replace the
deleted component with any one of the following:
• Family Table
• Interchange Group
• Layout
Remove - Removes the deleted member from the assembly.
Clip - Removes not only the deleted component, but all subsequent components in the Model Tree. 5.
6.
Place Back - Places the deleted component back in the mold model using its old constraints.
7.
The following task explains how to Reclassify mold model components:
1. Open reclassify.mfg

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2. Notice the round workpiece in the mold model. Notice also the rectangular mold base component.

Fig 3.31: Model for reclassifying

3. Click Mold Model > Reclassify from the menu manager. Select manual_wrk.prt and click OK from
the Select dialog box.
4. Click Workpiece > Done > Done/Return in the menu manager. Notice that there are now two
workpieces in the mold model.

Fig 3.32: Part converted into workpiece

5. Click Mold Model > Reclassify.

6. Select round_wrk.prt and click OK from the Select dialog box.
7. Click Mid Base Cmp > Done > Done/Return in the menu manager.

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8. Notice that there is now only one workpiece in the mold mode.

Fig 3.33: Round workpiett converted into part

The following task explains how to Remove Mold Component:

9. Select round_wrk.prt. right-c ·ciC and seiect Delete in the Model Tree.
10. Notice that the mold base componeN is removed from the graphics window and Model Tree.
11. Click Place Back in the menu manager.
12. Notice that the ROUND_WRK.PRT has beer plac� oack in the mold model using the last successful
placement.
1 3. With round_wrk.prt still selected, press Delete.
14. Click Remove in the menu manager.
15. Notice that the mold base component is removed from the mold model.

Fig 3.34: Mold component without round wor0<p"ttt

This completes the task.

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Mold Volume Creation

Once the reference model and workpiece have been assembled into the mold model, you must create mold
volumes within the mold model. Mold volumes are surfaces that locate a closed volume of space in the
workpiece and are ultimately used to create the final mold core, cavity and slider components.
Understanding Mold Volumes
A mold volume consists of surfaces that locate a closed volume of space within the workpiece. Because the
mold volume is comprised of surfaces, it has no solid material. Creating mold volumes is an intermediate
step for creating the final extracted mold components. Mold volumes are ultimately used to create the
final solid extracted mold components. They appear purple, when the model display is set to something
other than shading.
The following are some general information regarding mold volume creation:
• A mold volume can add or remove material.
• A mold volume is created as an assembly level protrusion or cut within the mold model.
• You can sketch mold volumes.
• A mold volume can be trimmed or split, using other surfaces.
• Mold volume creation is an iteractive process. You can create mold volumes at any time after the
workpiece is assembled, but before the final solid mold components are extracted.
Renaming Mold Volumes
When you create a mold volume, it is a best practice to rename it to something that helps you recognize
it within the Model Tree. To rename a mold volume, you can right-click in the graphics window and select
Properties after starting the mold volume creation tool. This causes the Properties dialog box to appear,
which enables you to edit the mold volume name.
Sketching Mold Volumes
You can create a mold volume by sketching its shape. Consider the following guidelines when sketching
mold volumes
The following task explains how to Sketch a mold volume in a mold model:
1. Open sketch-volume.mfg. and Select SKETCH-VOLUME_WRK.PRT click View > Display Style >

Wireframe from the main menu.

2. Click Add Mold Volume � from the Mo/dtoolbar.

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3. In the graphics window, right-click and select Properties. �a

- .ra og box, edit the Name
to PLUG_VOL and press ENTER.

Fig 3.35: Mold Model and Workpiece in Wireframe

4. Start the Revolve Tool 6� from the Feature toolbar. Right-click and select Define Internal Sketch.
5. Select datum plane mold_right as the Sketch Plane. Select Top from the Orientation drop-down list
and click Sketch.

Fig 3.36: sketch plane for mold volume

6. Click Hidden line @ and also click References -j!:l·

7. Zoom in and select the top workpiece surface, datum axis A_1 , the bottom of the plug and the angled
edge as shown below. Click Close in the References dialog box.

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Fig 3.37: References for sketch

8. Right-click and select Centerline. Sketch a vertical centerline on the axis reference. Click Line '
:h.
and sketch the five lines as shown. Click Done Section '../' .
·st
i
I
-¢- -(}

v
{_ .G>.
l[l v

!
! _
, �- 1- j_0 ' �.
I

Fig 3.38: Sketch for a Mold Volume

9. Click Complete Feature � in the dashboard. Click Apply Changes � from the Mofdtoolbar.

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10. Click No hidden ED and click Axis Display ,._ . Notice �:::::be� MOid volume will be a Ct
surface.
Th
alJ

Fig 3.39: Mold Volume created

11. Click Shading (J .

This completes the task.

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re a Creating Sliders using Boundary Quilts

The system can calculate undercut areas in the reference model and create boundary quilts to be used for
automatic slider creation.
• A slider is a special type of mold volume.
• Boundary quilts are created in undercut areas.
• Slider mold volume is created from the boundary quilt.
• Slider mold volume can be projected to a specified plane.

PULL DIRECTION PULL DIRECTION

Fig 3.41: Meshing a Boundary Quilt Fig 3.42: Slider Mold Volume

Fig 3.43: Slider Mold Volume Projeckd to Workpiece Surface

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What is a Slider?
A Slider is a mold component that helps account for undercuts in the reference model geometry. Undercuts
are features in the reference model that would prevent a conventional core-and-cavity mold from opening
after the molded part has been solidified. Sliders "slide" in from the sidtS to account for these undercuts
to keep the mold from locking when opening and closing or destroying the part. The action of these sliders
is called side action.

Creating Sliders using Boundary Quilts

In Pro/ENGINEER, a slider is a special type of mold volume that can be used to ultimately create the slider
mold component. One of the ways you can create sliders in Pro/ENGINEER is by using boundary quilts. To

create a slider mold volume using boundary quilts, you must start the Add Mold Volume � tool from
the Mold tool bar and then click Insert > Slider from the main menu.

The Slider Volume dialog box displays the reference part found in the mold model. If the mold model
contains more than one reference model, you must specify which one is to be used for the calculation.

You can also specify the pull direction. The system utilizes the mold model's pull direction as the default Pull
Direction, but you can specify a different pull direction by selecting any one of the following references:

• Plane - Makes the pull direction perpendicular to the specified plane.

• Curve, Edge, or Axis - Makes the pull direction follow the selected curve, edge or axis.
• Coordinate System - Makes the pull direction follow the specified axis of the selected coordinate
system.

The system creates boundary quilts in the areas where the undercuts occur and displays them in the
Exclude column of the Slider Volume dialog box. You can select each boundary quilt and perform the
following operations on each quilt:

• Mesh - Meshes the boundary surface in the graphics window.

• Shade - Shades only the boundary surface in the graphics window, temporarily hiding all other
geometry.

You can then add each quilt that you want to become a slider mold volume to the Include columl') of the
Slider Volume dialog box. The system automatically extrudes the slider mold volume based on the boundary
quilt.

Specifying the Projection Plane

Optionally, you can specify a projection plane for each slider mold volume. The system extends the extruded
slider volume u p to the specified projection plane, in the direction normal to the plane.

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The following task explains how to create a slider mold volume using boundary quilts in a mold model:
1. Open slider-calc.mfg. Select slider-calc_wrk.prt and click View > Display Style > Wireframe from
the main menu.

PULL DIRECTION

Fig 3.44: Mold component to create slider

2. Click Add Mold Volume � from the Moldtoolbar.

3. In the graphics window, right-click and select Properties.
4. In the Properties dialog box, edit the Name to CORNER_SLIDER and press ENTER.
te 5. Click Insert > Slider from the main menu.
6. In the Slider Volume dialog box, click Calculate Undercut Boundaries .@.. . Notice that one undercut
the area is found in the reference model.
the
-lnc:llde --- Eld.lde--­
I. Quilt 1
I:

»
«
1�

Fig 3.45: Undercut Ouiltl

7. In the Slider Volume dialog box, select Quilt 1 and click Mesh Selected Boundary Surfaces l�l .

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8. Notice that the quilt is meshed in the graphics window.

PULL DIRECTION

Fig 3.46: Boundary Surfaces meshed

9. In the Slider Volume dialog box, dick Shade Selected Boundary Surfaces .J
10. Click OK from the Shade Info dialog box.

PULL DI RECTION

Fig 3.47: Surface meshed

11. I n the Slider Volume dialog box, click Include Boundary Surfaces (;;] to include the quilt Click Apply

Changes _.,, .

12. Click Apply Changes _.,, from the Mold toolbar. Notice the slider mold volume that is created.

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Fig 3.48: Slider created

13. With the slider mold volume still selected, right-click and select Edit Definition.

14. In the Slider Volume dialog box, click Select Projection Plane �-...

15. Select the right surface of the workpiece as shown below.

PULL DIRECTION

Fig 3.49: Surface selected on mold volume to extend slider

16. Click Apply Changes � from the Slider Volume dialog box.

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17. Notice that the slider mold volume has extruded out to the selected surface.

PULL DIRECTION

Fig 3.50: Extended slider

This completes the task.

Sketching Slider Mold Volumes

You can also sketch slider mold volumes. The following the are reasons to sketch slider mold volumes:

Shape - When calculated u n dercut boundaries are used, the resulting slider mold volume takes on the
shape of the undercut geometry. If the shape is not desired for manufacturing or it cannot be manufactured,
a slider mold volume can be sketched to account for the undercut geometry.

Size - Since the slider mold volume created by calculating undercut boundaries takes on the shape of the
undercut. the slider mold volume may be too small for manufacturing.

Result - Depending on the reference model geometry, sometimes the slider mold volume obtained by
calculating undercut boundaries cannot be created or the slider mold volume does not entirely account
for undercut geometry.

Guidelines for Sketching Sliders

When creating slider mold volumes using sketch-based features, consider the following guidelines:

• You can still initially calculate the undercut boundaries for the reference model even when you are
sketching the slider mold volumes. The ana lysis helps you determine the locations in the mold, model
where sliders will be required and helps ensure that you have accounted for all undercut geometry.
• Ensure that the sketch you create accounts for the entire undercut geometry. That is, make sure that
the entire u n dercut geometry is contained within the resulting sketched slider mold volume. It can be
beneficial to utilize the sides of the undercut geometry as sketching references.
• Because the slider is just a special type of mold volume, you can use any sketch-based feature that is
available for sketching the conventional mold volume on the slider mold volume.
• Because the slider is a mold volume, the sketch must be dosed.

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Fig 3.51: Slider Volume too Small Fig 3.52: Incorrect Slider Result

Fig 3.53: Sketched Slider Mold Volumes

The following task explains how to Sketch Slider Mold Volumes in a mold model procedure:

1. Open slider-sketch.mfg.
2. Select the slider-sketch_wrk.prt and click View > Display Style > Wireframe.
3. The left slider volume, created by calculating undercut boundaries is too small to be manufactured, so
you must sketch a different slider mold volume.

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4. Select the left_slider_vol, right-click and select Suppress. 0 OK and de-select all geometry. 11.

12.
Fig 3.54: Slider Selected for suppress

5. Click Add Mold Volume �. Right-click and select Properties. Type LOWER_SUDER_VOL as the
Name and press ENTER.

·71
6. Start the Extrude Tool a, from the Feature toolbar.
7. Right-click and select Define Internal Sketch.
8. Select the front workpiece surface as the Sketch Plane.
9. Select Bottom from the Orientation drop-down list and dick Sketch.

13.
14.
1 s.

Fig 3.55: Plane selected to sketch slider sketch

10. Select datum planes MOLD_RIGHT, MAIN_PARTING_PLN and the left and right edges of the tab,
zooming in, if necessary.

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1 1 . Click Close from the References dialog box.

Fig 3.56: References for Sketch

12. Sketch, constrain and dimension the following sketch. Click Done Section .._,

the

Fig 3.57: Sketch for Slider

1 3 . Spin the model slightly and click Change Depth Direction X.

14. In the graphics window, right-click the depth handle and select To Selected.
15. Right-click to query and select the inner reference model surface.

Fig 3.58: Extruded slider

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16. Click Complete Feature � in the dashboard.

17. Click Apply Changes � in the Mold toolbar.

Fig 3.59: Extruded slider

Sketching second slider mold volume

18. Spin the model if necessary and zoom in on the right slider volume.
19. The right slider volume, created by calculating undercut boundaries, has not completely accounted for
the undercut created by the round.
20. Select the RIGHT_slider_vol, right-click and select Suppress. Click OK and deselect all geometry.

Fig 3.60: Second slider

2 1 . Click Add Mold Volume �.

22. Right-click and select Properties. Type UPPER_SUDER_VOL as the Name and press ENTER.
:;;
, ,
23. Start the Extrude Tool 0/ _ Right-click and select Define Internal Sketch.

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24. Select the right workpiece surface as the Sketch Plane. Select Bottom from the Orientation drop­
down list and click Sketch.

Fig 3.61: Plane selected to sketch

25. Select datum planes MOLD_FRONT and MAI N_PARTING_PLN as references.

26. Click Close from the References dialog box.
I

27. Click Centerline i and sketch a centerline on the vertical reference.

)r
28. Sketch, constrain and dimension the following sketch.

29. Click Done Section v .

Fig 3.62: Sketch for Slider

30. Spin the model slightly and click Change Depth Direction A.
31. In the graphics window, right-click the depth handle and select To Selected.

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32. Right-click to query and select the inner refercr.«

Fig 3.63: Extruded slider

...,
33. Click Complete Feature from the dashboard.
..,
34. Click Apply Changes from the Mold toolbar.
35. Press CTRL + D to orient to the Standard Orientation.

Fig 3.&l: � sfidtr- two sliders

This completes the task.

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Reference Part Cutout

You can create a reference part cutout on a mold volume by clicking Edit > Trim > Reference Part Cutout
from the main menu. A reference part cutout enables you to remove any overlapping reference model
geometry from the mold volume. The volume of the reference model is subtracted from the mold volume.
This is a very useful feature because the mold volume will then match the reference model geometry. A
reference part cutout enables you to create a mold volume that completely encompasses the desired area
of the reference model and then create a reference part cutout feature.

Creating a reference part cutout is not a requirement when creating mold volumes. The reference model
geometry is automatically cut out of the mold volumes when the volumes are split (this happens later in
the process). Creating a reference part cutout is a great method to help you determine, if the reference
geometry can successfully be cut out during the split process. It can also help you visually see whether you
have created a mold volume that captures the desired reference model geometry or not.

The reference part cutout option is only available if you are creating a volume or if you are redefining the
volume. The resulting reference part cutout feature appears in the Model Tree as a feature calledRefpart
Cutout id. However, the mold volume for which the trim was applied is also displayed in the Model Tree as
shown here:

+ � Extrude 1 [LOWER_SlIDER_VOl.1 - MOLD VOLUME]

+ � Extrude 2 [LOWER_SLIDER_VOL2 - MOLD VOLUME]
+ � Extrude 3 [UPPER_SUDER_VOL MOLD VOLUME]
-

� Refpart Cutout d
i 5016 [UPPER_SUDER_VOL - MOLD VOLUME]
+ Insert Here
Fig 3.65: Model Tree Cutout volume

Reference Part Cutout Tips

Consider the following tips when creating a reference part cutout for a mold volume:

• Without creating additional modifications to the volume after the reference part cutout, the system
makes the reference part cutout option unavailable. Therefore, you cannot cut out a volume twice.
• When more than one reference part is present, the system prompts you to select only one.

Fig 3.66: Reference Mold Model Fig 3.67: Mold Volume for Cutout

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Fig 3.68: Slider Cutout Created

The following task explains how to create reference part cutouts in mold volumes in a mold model:

1. Open refpart-cutout.mfg.
2. Select the refpart-cutout_wrk.prt and click View > Display Style > Wireframe.

3. Notice the rectangular hole in the bottom surface.

Fig 3.69: Reference shape to be cut

4. In the Model Tree, right-dick mold volume upper_slider_vol and select Unhide.
5. Notice that the mold volume completely consumes the rectangular cut, but it also occupies volume
in the reference model.
6. Notice that the surface of the mold volume is flat.

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Fig 3.70: Slider is selected for cutout

7. Select mold volume upper_slider_vol, right-click and select Redefine Mold Volume.
8. Click Edit > Trim > Reference Part Cutout from the main menu.

9. Click Apply Changes � from the Mo/d toolbar.

10. Notice the Refpart Cutout feature in the Model Tree.

Fig 3.71: Reference is selected to be cut

11. Select reference model refpart-cutout_ref.prt, right-click and select Hide.

1 2 . Notice that the reference model volume has been subtracted from the mold volume.

1 3 . Right-click refpart-cutout_ref.prt and select Unhide.

me

Fig 3.72: Slider with cutout

This completes the task.

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Lifter Mold Volumes

A Lifter is another mold component that helps account for undercuts of the inside of the reference model
geometry. Because mold components are ultimately created from mold volumes, you can use sketch-based
features to create lifter mold volumes in the mold model.
A lifter is usually attached to the moving side of the mold. It moves at an angle to free the plastic that
comprises the undercut inside the model. Due to their function, lifters are normally long and narrow.

Fig 3.74: Lifter created to account for Undercut

The following task explains how to Sketch lifter mold volumes in a mold model:
1. Open lifter.mfg and select the lifter_wrk.prt and click View > Display Style > Wireframe.
2. Notice the undercut created by the tab.

3. Click Add Mold Volume i=@ from the Mold toolbar.

4. Rename the mold volume as LIFTER_VOL1 .

Fig 3.75: Lifter to create mold model

,71
5. Start the Extrude Tool Cl,

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6. Right-click and select Define Internal Sketch.
7. Select datum plane MOLD_RIGHT as the Sketch Plane and click Sketch.
1odel
iased 8. Click Hidden line @

that

Fig 3.76: Sketch mode to create Lifter

n
:
9. Click References icon ·;_.· and select the bottom of the workpiece and the tab vertex as references.
Click Close.

10. Click Centerline icon and sketch a vertical centerline through the vertex reference.
11. Sketch a horizontal centerline below the vertex reference. Click No hidden ED .Click Plane Display

I11.J to disable their display.

12. Sketch, constrain and dimension the sketch, as shown below. Click Done Section -../'

Fig 3.77: Sketch for lifter

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13. In the dashboard, edit the depth to Both Sides. Eo·t 'n' ce_ -o B and click Complete Feature �

14. Click Shading CJ . Orient to the 3d view orientation.

Fig 3.78: Extruded lifter

15. Click Edit > Trim > Reference Part Cutout from the main menu.

16. Click Apply Changes � from the Mold coolbar.

Fig 3.79: Trmmed rtter

This completes the task.

The following task explains how to Sketcr a �er mola ·.oJurne �at accounts for the undercut in the mold
model:

1. Open lifter2.mfg.Select the lifter_wrk.prt and click View > Display Style > Wireframe.

2. Spin the model, as shown below and notice the undercut.

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3. Click Add Mold Volume � from the Mold toolbar.
4. Rename the mold volumeas LIFTER_VOL2.

Fig 3.80: Mold model for lifter

71
5. Start the Extrude Tool O,
6. Right-click and select Define Internal Sketch.
7. Select datum plane MOLD_RIGHT as the Sketch Plane and click Sketch.

8. Click Hidden line @ .

:n

9. Click References icon ·;o.;o· and select the bottom of the workpiece, the angled line at the bottom edge
of the tab, the rounded edge of the tab and the right edge of the hole as references. Click Close.

Fig 3.81 : References for sketch

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10. Click Line and sketch the shape on the references.

Fig 3.82: Sketch for lifter

1 1 . Click Shading J .Zoom in on the top of the sketch. Click Centerline and sketch a vertical

centerline through the vertex, second from left. Dimension the sketch, as shown.

1t
r

Fig 3.83: Sketch for lifter

12. Click Plane Display ID.I to disable their display.

13. Click Done Section v .
14. In the dashboard, edit the depth to To Selected. Spin the model so that you can see its underside and
select the surface to extrude to, as shown.

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Rg 3.84: Surface for Extrude

15. In the dashboard, select the Options tab. Edit the Side 2 Depth to To Selected and select the surface
to extrude to, as shown.

Fig 3.85: Extruded lifter

16. Click Complete Feature � .

17. Spin the model, as shown and notice that the lifter accounts for the undercut.

and

Fig 3.86: Extruded lifter

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18. Click Edit > Trim Reference Part Cutout �,.,

>

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19. Click Apply Changes from the Mold toolbar.

Fig 3.87: Trimming lifter

20. Select lifter_ref.prt, right-dick and select Hide.

21. Spin the model and view the lifter mold volume.

22. Click Save 191 from the Main toolbar and click OK to save t e model

23. Click File > Erase > Current and then click Se.ect All I a ; af1d OK to erase the model from
memory.

Fig 3.88: lifter

This completes the exercise.

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Replacing Surfaces and Trimming to Geometry

Replacing Surfaces
You can replace a single mold volume surface with a quilt surface by clicking Edit > Replace from the
main menu. You can use the Replace option to add volume, remove volume or add and remove volume
simultaneously.
By default, the mold volume is "consumed" by the replaced surface feature. That is, the mold volume is not
visible, but still exists previously in the Model Tree.
When using the Replace option, there is one option available in the Replaced Surface dialog box:
• Keep quilt - Enables the quilt selected for the replace to remain visible after the replace is created.
The Replace option is only available if you are creating a volume or if you are redefining the volume.
The resulting replaced surface feature appears in the Model Tree as a feature called Replaced Surface
id.
Trimming to Geometry
You can trim surfaces to other geometry in the mold model by clicking Edit > Trim > Trim To Geometry
from the main menu.
The Trim to Geometry option is only available if you are creating a volume or if you are redefining the
volume. The resulting trim to geometry feature appears in the Model Tree as a feature called Trim To Geom
id. However, the mold volume for which the trim was applied is also displayed in the Model Tree.
from
You can trim to geometry as an alternative, for extracting a mold volume up to a surface. However,
trimming to geometry has more powerful capabilities than just this use. Trimming can only remove volume,
but will not add volume.
When trimming surfaces to geometry, you must specify the following:
Ref Type - Specifies what the system uses as the trimming entity. You can specify any one of the
following:
• Part - Uses a part for trimming.
• Quilt - Uses a quilt for trimming.
• Plane - Uses a plane surface or datum plane for trimming.
Reference - Enables you to specify the item whose geometry will be used for trimming. The item that
you select depends on the Ref Type that was specified. Essentially, the Ref Type acts like a filter for the
Reference selection.
Direction - Enables you to select a trim feature direction. A direction arrow points in the direction, where
the volume will be trimmed at the reference. You can select the following references:
• Plane - Makes the direction perpendicular to the specified plane .
• Curve, Edge, or Axis - Makes the direction follow the selected curve, edge or axis.
• Coordinate System - Makes the direction follow the specified axis of the selected coordinate

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system.
Trim Type - Enables you to specify which side of the t• mm·ng '�-­ ::>e Jsed when trimming the
mold volume. You can select either of the following:

• Trim By First Reference lf,:!J I _ Trims the item by the

... cos·

• Trim By Last Reference F•j!_ - Trims the item by the as� •e:
Offset - Offsets the trimming reference along the direction c before tri mm i ng t h e
geometry.

Fig 3.89: Trimm·ng a Volume :o Gcooctrv

The following task explains how to Replace surfaces a"'c ••m u...,� ·o geometry in a mold model:
1. Open replace-trim.mfg. Select the replace-tri _ or. and cuck View > Display Style >
Wireframe.
2. Spin the model as shown below ano norce i at ie s� moa volume passes through the reference
model.

Fig 3.90: Slider for trimming

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3. In the Model Tree, select slider_vol 1 , right-click and select Redefine Mold Volume.
4. Click Edit > Trim > Trim To Geometry from the main menu.
5. In the Trim to Geom dialog box, select Quilt as the Ref Type.
6. Select the previously created quilt as the trimming entity.

Fig 3.91: Component selected for trimming

7. Select datum plane mold_front from the Model Tree as the Direction.
8. Click Flip from the menu manager until the arrow points towards the left. The volume to the left of
the trimming entity is to be removed.
9. Click OK from the menu manager.
>

Fig 3.92: Trimming direction

10. Click Apply Changes � from the Trim to Geom dialog box.

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1 1 . Notice that the slider mold volume has been trimmeo a�·� tr

Fig 3.93: Trimmed slider

This completes the exercise. 1.

Sketching Insert Mold Volumes 2.

3.
You can swap inserts out of the same core and cavity in the mold model to produce similarly shaped
parts.
•
Inserts are used as a cost saving measure.
• Inserts are used as a consideration for machining.
Because mold components are ultimately created from mold volumes, you can use sketch-based features
to create insert mold volumes in the mold model.

.
...

5.
Fig 3.94: Viewing the Completed Insert Fig 3.95: Viewing the Reference Model

6.

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Fig 3.96: Design Variations that can use same Core and Cavity

The following task explains how to create an insert mold volume in a mold model:
1. Open insert.mfg. Select the insert_wrk.prt and click View > Display Style > Wireframe.
2. Notice the square shape cut into the top of the model.
3. Notice that the insert_vol mold volume has been started and is partially filling the square shape.
ihaped

!atu res

Fig 3.97: Mold model with insert

4. Right-click insert_vol and select Redefine Mold Volume.

5. Start the Extrude Tool a

J.
6. Right-click and select Define Internal Sketch.

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7. Query-select the top of the existing mold volume as tn-e �--ttr »lane and click Sketch.

Fig 3.98: Plane selected for Sketch

8. Click Use Edge OJ and select Loop from the Type dialog box.
9. Query-select the main top surface of the reference model.
10. In the menu manager, click Next until the square loop is highlighted and click Accept.

1 1 . Click Close from the Type dialog box.

12. Click Done Section v

Fig 3.99: Sketch for Insert

13. Orient to the 3D view orientation.

14. Edit the depth to 20 and click Complete Feature �

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Fig 3.100: Extruded Mold volume

15. In the Model Tree, right-click Surface id 1 75 3 and select Unhide.

1 6. Click Edit > Replace from the main menu.
17. Query-select the bottom of the large, square, extruded volume.

Fig 3.101: Mold volume surface selected for Replace

18. In the graphics window, select Ouilt:F14.

19. Click OK from the Replaced Surface dialog box.

Fig 3.102: Mold volume replaced surface

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20. In the Model Tree, right-click Surface id 2746 and select Unhide. 31.
21. Click Edit > Replace.
32.
22. Spin the model and select the top of the large, square, extruded volume.
23. In the graphics window, select Quilt:F15.
24. Click OK from the Replaced Surface dialog box.

33.
Rg 3.103: Surface Replaced 34.
35.
25. Select insert_ref.prt, right-click and select Hide.
26. Orient to the Standard Orientation.
27. Click Edit > Trim > Reference Part Cutout.

\
Fig 3.104: Extruded Mold volume to Trim
I This

28. Click Edit > Trim > Trim To Geometry.

29. I n the Trim To Geom dialog box, select Quilt as the Ref Type.
30. Select LIFTER_VOL2 as the Reference.

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31. Select datum plane MOLD_FRONT as the direction and click OK from the menu manager.

32. Click Apply Changes _.,, from the Trim to Geom dialog box.

\
Fig 3.105: Extruded Mold volume Trimmed
I
33. Click Apply Changes _.,, from the Mo/dtoolbar.
34. In the Model Tree, right-click LIFTER_VOL2 and select Hide.
35. Spin the model and view the completed insert mold volume.

Fig 3.106: Mold volume insert

This completes the task.

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Parting Line and Parting Surface Creation Crea

A parting surface is a surface feature that you can use to split a wot.qiiece or an existing volume, including
You c<
surfaces of one or more reference parts. You can create parting swf-cees manually by using various basic
parti n
and advanced surface creation techniques. You can also create parting surfaces automatically by using the
the dr
skirt surface technique. The skirt surface technique requires parting lines that you can define by creating
certai
silhouette curves.
From
There are two different methods that you can use to create the parting surface:
Name
�
• Automatic - You can utilize the Automatic Parting Surface tool to create the parting surface
.=.;;./
defau
automatically. The parting surface created using this tool is called a skirt surface. Surfa,
• Manual - You can create the parting surface using basic and advanced surface creation techniques. refere
If you create the parting surface automatically using the skirt surface, it is necessary to first create a mode
parting line. The parting line is a collection of datum curves that is created on the reference model. You to be
can then use the parting line to create the skirt surface. Di red
There are two different methods that you can use to create the parting line: pull d
f
Automatic - You can utilize the Automatic Parting Line Q tool to create the parting line
•
•

automatically. The parting line created using this tool is called a silhouette curve. A silhouette curve is . (

a datum curve feature that is created where the draft on the reference model instantaneously changes . (
from positive to negative when viewed from a certain point. s
• Manual - You can create datum curves using various techniques in order to create the parting line. The f
curve
1. (
\

2. t

Fig 3.107: Automatic Parting line Created Fig 3.108: Parting Surface

You must remember the following criteria when creating parting surfaces:
• A parting surface must intersect the workpiece or mold volume completely. You can merge multiple
surfaces together.
• A parting surface cannot intersect itself.
• You can use any surface as a parting surface as long as the first two criterias are met.
• Parting surface features are created at the assembly level in the mold model.

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Creating an Automatic Parting line using Silhouette Curves

Jding
You can create an automatic parting line using the Automatic Parting Line O tool. This tool creates the
�asic
p the
parting line by using silhouette curves. A silhouette curve is a datum curve feature that is created where
the draft on the reference model instantaneously changes from positive to negative, when viewed from a
ating
certain direction.
From the mold model standpoint, you must define the following, when creating the silhouette curve:
Name - Defines the name of the curve as it displays in the Model Tree. If desired, you can accept the
default name.
Surface Refs - Specifies the surfaces on which the silhouette curve should be created. By default, the
reference model is defined as the surface references. Thus, the silhouette curve is created on the reference
model. If the mold model contains more than one reference model, you must specify the surface references
to be used and all the surface references must be selected on the same solid or reference model.
Direction - Defines the direction for creating the silhouette curve. By default, the specified direction is the
pull direction, although you can specify a different direction using any of the following options:
• Plane - Makes the direction perpendicular to the specified plane.
e is • Curve, Edge, or Axis - Makes the direction follow the selected curve, edge or axis.
nges • Coordinate System - Makes the direction follow the specified axis of the selected coordinate
system.
line. The following task explains how to create automatic parting lines in mold models using silhouette
curves:
1. Open auto-part-line.mfg. Select the auto-part-line_wrk.prt and click View > Display Style >

Wireframe.
2. Notice that the reference model contains a hole in its top surface as shown below.

iple

Fig 3.109: Mold compon,nt

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3. Click Automatic Parting Line Q from the Moldtoolbar:. -e dialog box that displays is
the Silhouette Curve dialog box.
4. Click OK from the Silhouette Curve dialog box.

Fig 3.110: Auto parting line

5. Select the auto-part-line_ref.prt, right-click and select Hide.

6. Spin the model and notice that the silhouette curve is comprised of two loops.

7. Click Close Window rEJ.

PULL DIRECTION

Fig 3.111: Silhouette curve

Create automatic parting lines in mold models using silhouette curves:

8. Open COVER-PART-LINE.MFG. Select the cover-part-line_wrk.prt and click View > Display Style >
Wireframe.

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9. Notice that the reference model contains four circular holes and one rectangular hole as shown
I is below.

Fig 3.112: Mold component

10. Click Automatic Parting Line Q from the Mold toolbar.

11. Click OK from the Silhouette Curve dialog box.

Fig 3.113: Parting line created

12. Zoom in on the top of the model and notice that there is a curve around each hole in the top
surface.

�e >

Fig 3.114: Parting line created for holes

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13. Orient to the 30 view orientation.

14. Notice that there is another curve around the entre bo
1 5. Notice that there is only one silhouette curve featurt <:rt:4ttil • �el Tree.

PULL DIRECTION

\ I
Fig 3.115: Parting line created

16. Orient to the FRONT view orientation.

17. Click Hidden line t§:I .

18. Notice that there is a curve created at �ery location, wriere tne draft instantaneously changes from
positive to negative.

19. Click Shading 0

Fig 3.116: Parting line in Wireframe

This completes the task.

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Analyzing Silhouette Curve Options: Slides
The Slides option enables you to specify mold volumes that already account for undercut geometry zones
in the reference model.
The system excludes silhouette curve creation at slides.
Recall, that a silhouette curve is created in a mold model where the draft on the reference model
instantaneously changes from positive to negative when viewed from the pull direction. Because undercut
areas can also cause draft to instantaneously change, the system may also create the silhouette curve
along undercut geometry zones.
The Slides option enables you to specify mold volumes that already account for undercut geometry zones
in the reference model. When mold volumes are specified, the system automatically excludes these
unnecessary edges and creates correct parting curves.
The following task explains how to analyze silhouette curve options by slides:
1. Open curve-slides.mfg. Select the curve-slides_wrk.prt and click View > Display Style >

Wireframe.
2. Notice that the mold model contains three slider mold volumes as shown below.

from

Fig 3.117: Mold component with Sliders

3. Start the Automatic Parting Line Q tool from the Mold toolbar.
4. Click Preview from the Silhouette Curve dialog box.
5. Notice that the system attempts to create the same silhouette curves for the undercut geometry that
the slider mold volumes already had created.

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Fig 3.118: Parting line Created for Sliders

6. In the Silhouette Curve dialog box, select Slides and click Define.
7. Press CTRL and select the three slider mold volumes.
8. Click Done Refs > Done/Return from the menu manager.

Rg 3.119: Selected Sliders

9. Click OK from the Silhouette Curve dialog box.

Fig 3.120: Parting line Created

This completes the task.

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Analyzing Silhouette Curve Options: Loop Selection

The Loop Selection option enables you to control the location of the curve segments in reference to the
part edges and specify which loops are included in the curve.

Loop selection:

• Loops created at every shutoff location.

Status options:

• Included
• Excluded
Chain selection options:

• Upper
• Lower
• Single

Fig 3.121: Included versus Excluded Loops Fig 3.122: Upper versus Lower Chains

Including and Excluding Silhouette Curve Loops

During silhouette curve creation, the system may create curves along edges that you do not want to
include. You can selectively remove curves along the edges that you do not want curves created, using the
Loop Selection option in the Silhouette Curve dialog box.

Selecting the Loop Selection option causes the Loop Selection dialog box to appear. The Loops tab in the
Loop Selection dialog box lists the loops of curves which comprise the silhouette curve and whether their
status is Included or Excluded. When you select a loop in the dialog box, it will be highlighted in the mold
'
model.

Loops are typically created at every location in the mold model where there is a shutoff. A shutoff is any
surface where the mold core and cavity gets in contact. When the mold closes the core and cavity, it
creates a seal that shuts off that area of the mold. One loop typically is created along the exterior of the
reference model. Other loops are created at each interior hole or cut. Loops are also created at areas of
undercut geometry.

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Loops are, by default, included in the final silhouette curve, although you can exclude any loop from the 6. Nol
final silhouette curve. The most common reason loops are excluded is because the shutoff at that specific 7. Not
1001
location is being formed by a slider or saddle.

Specifying Edges for Silhouette Curve Creation

When the system encounters a vertical surface or a surface that has no draft for which a silhouette curve
loop is to be included, the system may select the wrong edge to create the silhouette curve along. In most
cases you can change which edge to create the silhouette curve along. The following status options are
available:

• Upper - The chain is currently located at the uppermost edges of a vertical surface. The upper edge
is hig her, relative to the positive Z-axis or pull direction.
• Lower - The chain is currently located at the lower most edges of a vertical surface. The lower edge
is lower, relative to the positive Z-axis or pull direction.
• Single - You cannot move the chain for a single location, because the edges that the chain lies on
are associated with a drafted surface.

8.
The Chains tab in the Loop Selection dialog box displays both the chain number and its status. The chain I n ti
number is displayed as A-B, where A is the corresponding loop number from the Loops tab that the chain
9. Not!
belongs to and B is an incremental number for multiple chains belonging to a single loop, starting with 0.
10. You
For example, if there are three chains belonging to loop number 1, then the three chains are n u mbered as
1-0, 1 - 1 and 1-2. excl

1 1 . In tt
The following task explains how to analyze silhouette curve options by loop section:

1. Open loop-selection.mfg. I n the Model Tree, right-click loop-selection_wrk.prt and select Hide.

2. Start the Automatic Parting Line Q tool from the Mold tool bar.
3. Click Preview from the Silhouette Curve dialog box.
4. Notice the silhouette curve that is to be created.

12. In tr
the •

13. Agai
exch

14. In th

Fig 3.123: Auto Parting line selected

5. In the Silhouette Curve dialog box, select Loop Selection and click Define.

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6. Notice that the Loop Selection dialog box contains three loops. Select loop number 1 .
7. Notice that this outer loop highlights in blue color in the graphics window. We need to keep this
loop.

t
e

1e

Jn
Fig 3.124: Loop Selection

�n B. In the Loop Selection dialog box, select loop number 2.

1in
9. Notice that this loop is on the right side of the opening.
0.
10. You will later handle this opening using a method other than silhouette curves, so it needs to be
as
excluded from the silhouette curve.
11. In the Loop Selection dialog box, click Excluded.

·.! Loop ''>'!ler !ton 1><1

Tc
Loops OM1ins ·
-

INo. IStatus I I
11 Included I
3 Included

Fig 3.125: Loop selection dialog box with exclude

12. In the Loop Selection dialog box, select loop number 3 and notice that this loop is on the left side of
the opening.

13. Again, you will handle this opening using a method other than silhouette curves, so it needs to be
excluded from the silhouette curve.
14. In the Loop Selection dialog box, dick Excluded.

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1 Loop �elect1on x
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I.oops T aiar.s You can
INo. IStatus
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I I
-

I�
lr.Wded The skit
(>d.ided
selectec
Creati1
You car
Fig 3.126: Loop Selection dialog box with Exclude
tool bar.

Switch the location of chains for a loop in a silhouette curve Surface

You car
15. In the Loop Selection dialog box, select the Chains tab. Notice that you can only see the chains for tool.
included loops. Select the chain number 1 -0.
The par
16. Notice that its status is Single. This chain is on a drafted surface and cannot be changed.
can thil
17. In the Loop Selection dialog box, select chain number 1 - 1 . Press CTRL and select chain number 1-2.
cavity.
Notice that both their Status is Upper.
In order
18. Notice that both chains are to be created on the upper edges of the vertical surfaces.
curves i
One By
Curve C
Feat Ct
The ski1
curve i�
entire s
you car
Fig 3.127: Side Loops selected
The Re.
19. In the Loop Selection dialog box, click Lower, to switch both chains to the lower edges of the vertical proces�
surfaces and then Click OK. The Rel
20. Click OK from the Silhouette Curve dialog box. mold rr
Once y
types:
Inner I
Outer

Fig 3.128: Silhouette curve created lower

This completes the task.

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Skirt Surface

You can use a skirt surface to automatically create the mold model parting surface.
The skirt surface is created using specified datum curves. The silhouette curve parting line is usually
selected.
Creating a Skirt Surface
You can create the parting surface for a mold model by using Create Parting Surface � in the Mold
toolbar. The system can help you to create a parting surface automatically by using the Automatic Parting
-0-:
Surface = tool. This tool helps you to create a parting surface automatically by creating a skirt surface.
You can also click Edit > Skirt Surface from the main menu once you have started the Parting Surface
tool.
The parting surface is ultimately used to split the mold model into the mold core and mold cavity. So you
can think the parting surface as the location of all metal-to-metal contact between the mold core and
cavity.
In order to create the skirt surface, you must specify the curves that the system should use. You can specify
curves in any one of the following ways:
One By One - Enables you to select individual curves or edges.
Curve Chain - Enables you to select a chain of curves.
Feat Curves - Enables you to select all curves that belong to the specified feature.
The skirt surface is usually created by specifying a n existing parting line silhouette curve. The silhouette
curve is selected using the Feat Curves method of specifying curves. However, if you do not want to use the
entire silhouette curve or if you want to use the silhouette curve in conjunction with other datum curves,
you can use the Curve Chain or One By One options.
The RefModel, Workpiece and Direction must also be defined to create the skirt surface. However, if the
process workflow has been followed, these items should have already been automatically defined for you.
The Ref Model is the reference model used in the mold model, the Workpiece is the workpiece used in the
mold model and the Direction is the pull direction of the mold model.
Once you have specified these items, the system classifies each closed loop of curves into one of the two
types:
Inner loops - Loops that are filled by the skirt surface.
Outer loops - Loops that the skirt surface extends outwards.

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Usually, the system is automatically able to determine the loop classifications. Once the classifications are
made, the system automatically creates the skirt parting surface feature by doing the following:
• It fills the inner holes (shutoffs) in the reference model using the inner loops from the silhouette curve
or other selected datum curve.
• It extends the outer loops of the silhouette curve or other datum curve to the boundaries of the
workpiece.
Similar to mold volumes, you can rename the parting surface by starting the Parting Surface tool, right­
clicking and selecting Properties.
The following task explains how to create a skirt surface in a mold model and modify the silhouette
curve:
1. Open skirt-surface.mfg. Select the skirt-surface_wrk.prt and click View > Display Style >

Wireframe.
2. Select the silhouette curve that has already been created.
3. Notice that the silhouette curve consists of six loops - one around the entire reference model and one
loop each, for each interior shutoff.

I
Fig 3.129: Silhouette curve selected for parting surface

4. Click Create Parting Surface � from the Mo/dtoolbar.

;Q'
5. Start the Automatic Parting Surface .=./ tool from the Mold toolbar.
6. Select the silhouette curve and click Done from the menu manager.
7. Click OK from the Skirt Surface dialog box.

8. Click Apply Changes � from the Mo/dtoolbar.

9. Notice that all five interior silhouette curve loops have been filled by the skirt surface.
10. Notice also that the skirt surface has been extended from the outer silhouette curve loop to the sides
of the workpiece.

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lie

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tte

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Fig 3.130: Viewing the Parting surface

11. Spin the model so that you can see the underside of the reference model.
e

Fig 3.131: Oriented view for the Parting surface

This completes the task.

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Analyzing Skirt Surface Options: Extend Curves

1.
The Extend Curves option provides a further level of control mat enab es you to exclude curves from being
extended during skirt surface creation.

• By default, all selected curves are included.

•
The Extend Curves option enables you to exclude curve segments..

2.

3.
Fig 3. 132: Defautt Skirt Surface ..
-

Fig 3.133: Curve Segments Excluded Fig 3.134: Additional Curve Segment Excluded
5.
By default, all curves selected for the skirt surface are extended either inward or outward to create
6.
the surface. The Extend Curves option provides a further level of control to exclude curves from being
extended.
The Extend Curves tab in the Extension Control dialog box contains two columns:
• Include Curve - Specifies which curve segments are extended in the skirt surface.
• Exclude Curve - Specifies which curve segments are not extended in the skirt surface.

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The following task explains how to exclude curves from a skirt surface in a mold model:
l. Open extend-curves.mfg. Notice the silhouette curve that has already been created.
being
PULL DIRECTION

Fig 3.135: Curve for parting surface

2. Click Create Parting Surface c::i from the Mo/dtoolbar.

'°'
3. Start the Automatic Parting Surface ..;.;;..= tool from the Mold toolbar.
4. Select the silhouette curve and click Done from the menu manager.

Fig 3.136: Curve selected parting skirt surface

5. Click Preview from the Skirt Surface dialog box.

6. Click Repaint Ld . Notice that the surface extends out from all the curve segments of the silhouette
curve.

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Fig 3.137: Parting skirt surface created

7. In the Skirt Surface dialog box, double-click Extension.

8. In the Extension Control dialog box, select Curve 2 1 3 .
9. Notice that the curve segment highlights in the graphics window as shown.

1 7.

18.

19.

20.
Fig 3.138: Curve Excluded

10. I n the Extension Control dialog box, press SHIFf and select Curve 216.

11. Notice that a l l the four curve segments are selected and highlighted in the graphics window a s shown
in Fig: 3 . 1 39.

12. Click Exclude Curve � to exclude these curve segments.

This t

Fig 3.139: Curve Excluded

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13. Click OK from the Extension Control dialog box.
14. Click OK from the Skirt Surface dialog box.

1 5. Click Apply Changes � from the Mold toolbar.

16. Notice that the skirt surface is not created through the excluded curve segments.

Fig 3.140: Curve Excluded with skirt surface

17. Edit the definition of Skirt Surface id.

18. In the Skirt Surface dialog box, double-click Extension.

19. In the Extension Control dialog box, select Curve 2 1 3 and click Include Curve � and click OK.
20. Click OK from the Skirt Surface dialog box.

own

Fig 3.141: Parting skirt surface created through the parting line

This completes the task.

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The Tangent Conditions option enables you to �� -! "eference model to which the
resulting skirt surface must be a tangent.
• Specify which surfaces the skirt surface must oe :a-:� • -
2.
• You can exclude adjacent curve segments from the :a _

You must specify the following when defining tangent ro::! -

.. ·,,.., surface: 3.
...
.
• Tangent surfaces - Specify the reference model sura<:es o.
5.
skirt surface must be a tangent.
• Include Curve - The skirt surface must extend through tnest o.m� - - _�..• to the adjacent surfaces.
6.
By default. all curves adjacent to the selected surfaces are .. lJ1itod.
7.
• Exclude Curve - The tangent condition is not applied to tre �NCS ... s column of the Tangent
Condition tab.

Scl

8.
Fig 3.142: No Tangent Condition applied to Skirt Surface Fig 3.143: Tangent Co::cLIC': applied to Skirt Surface
9.
10.

11.
12.

Fig 3.144: Curves Excluded from Ta�t Condition

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The following task explains how to set tangent conditions for a skirt surface in a mold model:
1. Open tangent-cond.mfg. Select the tangent-cond_wrk.prt and click View > Display Style >
he
Wireframe.

2. Click Create Parting Surface p from the Moldtoolbar.

'D:
�
3. Start the Automatic Parting Surface tool from the Mold toolbar.
4. Select silhouette curve PART-LIN E and click Done from the menu manager.
he
5. Click OK from the Skirt Surface dialog box.

es. �
6. Click Apply Changes . from the Moldtoolbar.
7. Notice that the parting surface extends normal to the workpiece boundary as shown below.
�t

Fig 3.145: No Tangent Condition applied to Skirt Surfa�

Set Tangent condition for skirt surface

8. Edit the definition of Skirt Surface id.
9. In the Skirt Surface dialog box, double-click Extension.
10. In the Extension Control dialog box, select the Tangent Conditions tab.

11. In the Tangent Conditions tab, click Select Tangent Surfaces W.

12. Press CTRL and select the eight outer surfaces that are adjacent to the silhouette curve as shown.

Fig 3.146: Surface selected for Tangent reference

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13. Click OK from the Select dialog box.

14. Click OK from the Extension Control dialog box.
15. Click Preview from the Skirt Surface dialog box.
'o. 'Spm \nt moot\ ano no\.\t.t \'T\a\. t'nt -:.�\rt. s�nat.t no'N t"1..ttnd-:. tnt. tar.(!t.r.t to the. surtact.s ad\acent to
the silhouette curve.
17. Press CTRL + 0 to orient to the Standard Orientation.

PULL DIRECTION

Fig 3.147: Tangent Condition applied to Skirt Surface

This completes the task.

M
Analyzing Skirt Surface Options: Extension Directions
Yo
You can add or modify the direction that the skirt surface extends from the silhouette curve segments. (0

Extension directions can significantly alter the shape of the skirt surface. Arrows denote the direction at "
each segment vertex.
Lo
po
• Yellow - Default direction
• Orange - User-defined direction
Oi.1
an
• Green - Tangent direction
Select location and direction reference. •

Cf

Fig 3.148: Viewing Default Extension Directions Fig 3.149: Viewing User-Defined Extension Directions

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Fig 3.150: Extended Skirt Surface

By default, when the skirt surface extends from a silhouette curve, it extends normal to the curve. The
direction of extension is defined at each curve segment endpoint. If the directions at the curve endpoints
overlap, the skirt surface will fail.
You can modify the direction of extension for the curve endpoints in the Extension Directions tab of the
Extension Control dialog box.
When you select the Extension Directions tab, the extension directions for each of the curve segment
endpoints will be displayed i n the graphics window.
Modifying and Adding Extension Directions
You can modify extension directions as a means, to solve a failing skirt surface or you can modify them simply
to modify the shape of the resulting parting surface. You can also add additional extension directions.
In order to modify or add an extension direction, you must specify the following:
Locations - You can select either an existing included extend curve endpoint or you can create a datum
point at a new location, where you want to add an extension direction.
Direction reference - Specifies the direction in which the skirt surface will be extended. You can select
any one of the following references:
• Plane - The skirt surface is extended perpendicular to the plane. You can select either datum planes
or planar surfaces.
• Curve, Edge, or Axis - The skirt surface is extended along the direction of the specified curve, edge
or axis.
• Coordinate System - The skirt surface is extended along the specified coordinate system axis, which
you need to specify.
Each added or modified extension direction appears i n the Extension Directions tab as a point set. For each
defined point set, you can perform the following operations:
• Remove - Enables you to remove the point set.
• Redefine - Enables you to select a different location for the point set.

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• Direction - Enables you to select a different direcfoo :e'ttmcc.

You can also add new point sets.
Thefollowing task explains how to Modify and add extensi«I at��ms. m a skirt surface i n a mold
model:
1. Open extend-dir.mfg. Select the EXTEND-DIR_WRK.PRT a.'lG View > Display Style >
Wireframe.
2. Click Create Parting Surface p and start the Automatic Parting Surface � tool.
3. Select the silhouette curve and click Done from the menu mana�r.
4. Click Preview from the Skirt Surface dialog box.
5. Notice that the skirt surface fails.
6. Also notice the warning message in the message window as shown be.o.v.

+Select a featu'e ccriallilQ CU"VeS.

+Al elemerts have been de&ed. Select element(s) « adiar(s) frm daloo box.
l]camot extend sec;J'l'lellt(s). Erter Extension step to resdlle the issue.

Fig 3.151: Mc$sagc window

7. In the Skirt Surface d ialog box, double-dick the Extension.

8. Notice the warning message and also notice where the problem is occurring, based on the high lig hted
curve segments.
9. Click OK from the Warning dialog box.

Fig 3.152: Model for analyzing

10. Select the Extension Directions tab.

1 1 . Notice the default direction arrows at the problem area, at the lower rig ht which are pointing along
two different directions.

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Fig 3.153: Analyzing along two different directions.

12. In the Extension Directions tab, click Add. Select the vertex as shown and click Done from the menu
manager.

ted

Fig 3.154: Selecting vertex which is along both the directions

13. Select the right workpiece surface and click OK from the menu manager.
14. Notice the new user-defined direction at the vertex.

ong

Fig 3.155: Created single direction

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15. Click OK from the Extension Control dialog box.

16. Click Preview from the Skirt Surface dialog box and rotate �r:e rnooel. to observe the parting surface.

23.
24.

Fig 3.156: Skirt Surface 25.

26.
Add an extension direction to a skirt surface
17. Orient to the BACK view orientation.
18. Notice that the bottom of the skirt surface curves upward.
19. Orient to the 3 D view orientation.

27.
28.

Fig 3.157: Skirt Surface 3d View

20. Click Plane Display ILZJ and Point Display )( :.,

)( to enable their display.
21. In the Skirt Surface dialog box, double-click Extension and select the Extension Directions tab. Click
Add and select datum point PNTO.Click Done from the menu manager.
22. Select datum plane extension_dir and click OK from the menu manager.

Thi:

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1rface.

Fig 3.158: Direction indicated on plane

23. Notice the new user-defined direction and click OK from the Extension Control dialog box.
24. Click OK from the Skirt Surface dialog box.

�
25. Click Apply Changes from the Mold toolbar.
26. Spin the model and observe the skirt surface.

Fig 3.159: Extension surface

27. Click Plane Display IL1.J and Point Display ><><:,, to disable their display.
28. Orient to the BACK view orientation and notice that the surface no longer curves upward.

Click

Fig 3.160: Oriented view

This completes the task.

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Analyzing Skirt Surface Options: Shutoff Extension Sp�

You can specify a location other than the workpiece boundaries where the skirt surface extends to.
Shutoff Extension options:
Shutoff Plane - Shutoff extension extends up to the shutoff plane.
Draft Angle - Applies draft to Z-direction, shutoff extension surfaces.
By default, the outer loops of a specified silhouette curve are extended to the boundaries of the workpiece.
This may cause an undesirable shape in the resulting core and cavity mold components.
You can specify a shutoff extension, to stop the skirt surface from extending all the way out to the 2..
workpiece boundaries by using the Shutoff Ext option in the Skirt Surface dialog box. \he Shutoff E.xt
option enables you to specify the amount of extension towards the workpiece boundaries that the skirt
surface will undergo before stopping, extending in the pull direction and finally stopping at the workpiece
boundaries. There are two methods available for specifying the shutoff extension location:

Shutoff Dist - Specifies a uniform offset value around the silhouette curve perimeter that the skirt
surface will extend.

�ounaary - tna't>\es '/\)U \t) S?tt\� 'l�\lt �'tm bQ\1\\da{'{ that the. skirt surface will extend out to. You can
use either of the following two methods to specify the boundary:
• Select - Enables you to select an existing sketch as the boundary.
• Sketch - Enables you to sketch the boundary on-the-fly by specifying the sketch plane, reference
plane and reference direction.
�\>e6r,jm9 \n� �nu\�� �\c.��
The Shutoff Plane option is used in conjuncf1on w·1'tn 't'ne �'nu't'\>'li b'tt,l'l�'lt>"tl t>
�� �
�����
��
the planar reference that the shutoff extension extends to. The shutoff extension extends in the po"" - ...�. ­
·"""
negative Z-axis (pull direction) up to the shutoff plane and finally extends outward again to the wo
boundaries.
While the ShutOff Plane is optional in the Skirt Surface dialog box, it is a required reference, if a
extension is defined. Without the shutoff plane defined, the shutoff extension does not extend at an
the Z-axis and therefore is not used.
The following rules apply to the shutoff plane reference specified:
• The reference which you specify must be planar.
• There can be only one shutoff plane specified.
• The shutoff plane must be normal to the pull direction.
• The shutoff plane may be above the skirt surface. However, the resulting extension may not
validgeometry for a mold parting line.

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Specifying the Draft Angle
The Draft Angle option is also used in conjunction with the Shutoff Extension option, although it is not
a requirement. The draft angle option drafts the Z-di rection surfaces of the shutoff extension by the
specified draft angle value. You might need to apply a draft angle to these surfaces, to help with wear in
the resulting mold core and cavity. Note that you can only specify a positive draft angle.
The following task explains how to create a shutoff extension in the skirt surface of a mold model:
1. Open shutoff-ext.mfg. Select the shutoff-ext_wrk.prt and click View > Display Style >

Wireframe.
2. Notice the skirt surface shape.

Fig 3.161: Mold component with skirt surface

3. Edit the definition of Skirt Surface id to 1 501.

4. In the Skirt Surface dialog box, double-click ShutOff Ext.
5. In the menu manager, click Shutoff Dist, type the value as 2, and press ENTER.

6. Click Preview from the Skirt Surface dialog box and click Repaint Gt] . Notice that there is no
difference in the skirt surface shape.

Fig 3.162: Mold component with skirt surface after Shutoff Dist

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7. In the Skirt Surface dialog box, double-click Shutoff Plane. Select datum plane SHUTOFF and click
Done/Return from the menu manager. Click Preview.

8. Click Repaint Lld and notice that the shutoff extension now extends to the shutoff plane as shown
below.

14.
15.
16.
Fig 3.163: Mold component with skirt surface extended upto shutoff plane
17.

9. In the Skirt Surface dialog box, double-click Draft Angle. Type the value as 6, press ENTER and click
Preview.
10. Click Repaint Cl] and notice that the shutoff extension surfaces have been drafted as shown.

Sele!
Fig 3.164: Skirt surface with Draft angle 18.
19.
Select a new shutoff extension boundary
20.
1 1 . Double-click Shutoff Ext.
21.
12. In the menu manager, click Boundary > Select > One By One.
22.
13. Query-select the entire SHUTOFF_BOUNDARY sketch and click Done from the menu manager.

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click

own

Fig 3.165: Mold component with skirt surface and Shutoff boundary

14. Click Preview from the Skirt Surface dialog box and click Repaint [;] .
15. Notice the new shutoff extension shape.
16. Notice that the shutoff extension still extends to the shutoff plane.
17. Notice that the shutoff extension surfaces are still drafted.
click

Fig 3.166: Skirt surface having shape of curve

Select a new shutoff extension boundary

1 8. Double-click Shutoff Ext.
19. In the menu manager, click Boundary > Sketch.
20. Select the top workpiece surface as the sketch plane.
21. Click OK > Default from the menu manager.
22. Select datum plane MOLD_FRONT and the left workpiece edge as references and click Close from the
References dialog box.

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Am
Whe
aesi!
Tool:

Fig 3.167: Sketch plane for Shutoff extension S etch

•

•
23. Click Centerline and sketch a centerline on the horizontal reference.
24. Sketch, constrain and dimension the sketch, as shown below. Whe
desi�
surfa
Extc
You 1

Exte
optic
•

Fig 3.168: Shutoff extension Sketch

•

25. Click Done Section v.

26. Orient to the Standard Orientation. •

27. Click OK from the Skirt Surface dialog box.

Exte
norn
Trin

As
a SU
ome

Fig 3.169: Skirt surface Shutoff extension

This completes thetask.

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Analyzing Surface Editing and Manipulation Tools

When working with surfaces, it is often necessary to edit and manipulate quilts to achieve your desired
design intent.
Tools include:
•
Extend
• Trim
• Copy and Paste
• Offset
•
Mirror
• Merge
When working with surfaces, it is often necessary to edit and manipulate quilts to achieve your desired
design intent(sentence repeated again) You can use the following tools to edit and manipulate the
surfaces.
Extending Surfaces
You can extend a quilt using either of the following methods:

Extend Original Surface c:::i - Extends the surface boundary edge chain along the original surface. This
option has three additional options that determine how the extension is created:
• Same - Creates the extension of the same type as the original surface (for example, plane, cylinder,
cone or spline surface). The original surface is extended past its selected boundary edge chain and
does not create an additional surface patch. This is the default extend option.
• Tangent - Creates the extension as a ruled surface that is tangent to the original surface. With this
option an additional surface patch will be created.
• Approximate - Creates the extension as a boundary blend between the boundary edges of the
original surface and the edges of the extension. This method is useful when extending the surface
up to a vertex that does not lie along a straight edge. With this option an additional surface patch is
created.
Extend Surface To Plane �
r;;:till
- Extends the boundary edge chain up to a specified plane in the qirection
normal to this plane. With this option an additional surface patch will be created.
Trimming Surfaces
A surface trim is analogous to a solid cut, except that it trims away a portion of a surface. You can create
a surface trim as extrude, revolve, sweep, blend and so on. You can also trim a selected surface quilt using
other geometry such as planes, quilts and curves or edges.
Once you have specified the surface to be trimmed and the entity to do the trimming, you must specify
which side it has to be kept. You can opt to keep on one side, the other side or both sides.

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Copying and Pasting Surfaces

Copying and pasting surfaces enables you to create a� � ri :: � so that you can then perform
manipulations to the copied surface. You can copy and oas<:� s.::F� surface set, either from a quilt

or a solid. You can use either CTRL + C and CTRL + V or :r� Copf � :aaste liJ icons from the Main
toolbar. You should only use the Copy functionality in fi'E� - ;:.o not have proper references
to create the parting surfaces. The copy functionality car �:.· c: -c:.s:....:;;ce features, especially when
you are working with a complex design.
Offsetting Surfaces
You can create a surface quilt offset a distance value from ar� ,_,_ - � a solid surface. The offset
surface remains dependent on the original surface. When offseutr-; s__:....:as, lOJ can specify the fit type
either as Normal to Surface, Automatic Fit or Controlled Fit
Mirroring Surfaces
You can transform a surface quilt by mirroring it. To mirror a quilt, se.ecz:.� _ · and start the M i rror Tool
)IC , specifying a reference plane for the mirror. A new surface fean.-e oe created.

Merging Surfaces
You can merge two or more intersecting or adjacent quilts to createsu� t 2-sided edges. Merging
surfaces is covered more in detail in other topics.
The following task explains how to Modify a surface quilt using va ·o.:!S en:..;�..g and manipulation tools.
1. Open edit-manipulate.prt. Select feature Revolve 1 and seiecr � mo surface edge.
2. Click Edit > Extend from the main menu.

3. In the dashboard, click Extend Surface To Plane 1-:j} and se.ecr c.c;rum plane EXTEND.

Fig 3.170: Extending a surfa� up to Plane

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4. Click Complete Feature from the dashboard.
5. Deselect all geometry.
ilt

1in
:es
en

;et
'Pe

>ol Fig 3.171 : Extended Surface to Plane

Trim Surface in part model

6. Select Revolve 1 .
7. Select Quilt:FS.
ng
8. Click Edit > Trim from the main menu. Select the projected curve.

Fig 3.172: Sketch for trimming surface

�
9. Click Complete Feature . Deselect all geometry.

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Fig 3.173: Trimmed surface

Mirror surface quilt

10. Select Revolve 1 and select Ouilt:FS. Copy ;

11. Start the Mirror Tool jlC from the Feature toolbar and select datum plane MIRROR. 6. 0

.., 7. Ee
12. Click Complete Feature and deselect all geometry.
8. Q
9. Ps

Rg 3.174: Mirrored surfa�

Offset a quilt in the part model

1. Select Revolve 1 and select Quilt:FS. 10. Pr
2. Click Edit > Offset from the main menu.
3. In the dashboard, type 40 as the Offset value and press ENTER. 11. c
12. In
..,
4. Click Complete Feature

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5. Deselect all geometry.

Fig 3.175: Offset surface

Copy and Paste a portion of surface quilt

6. Click Plane Display ILlJ to disable their display.

7. Edit the selection filter to Geometry.
8. Query-select the lowest surface of the mirrored quilt.
9. Press CTRL and query-select the highest surface of the mirrored quilt.

Fig 3.176: Surfaces to copy

10. Press CTRL + C to copy the surfaces and press CTRL + V to paste the surfaces.
�
11. Click Complete Feature .
12. In the Model Tree, select Mirror 1 , right-click and select Hide.

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Mer�

There
• Ir
b
• J1
t1
The fc
1. c
2. p

Fig 3.177: Copy Paste surface

3. s

This completes the task. 4. 11

Merging Surfaces 5. (

Merging a quilt is required for operations such as creating solids from quilts.
Colors:
• Pink = One-sided edges.
• Magenta = Two-sided edges.
Merge makes one-sided edges two-sided.
Merge options:
• Intersect
• Join

6.

7.

Fig 3.178: Surface Merge Keep Options

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Merge Options
There are two types of merge operations, used for different surface geometry:
• Intersect - Primarily used for intersecting quilts, when a trimming effect is desired, although it can
be used on adjacent quilts.
• Join - Recommended for use on adjacent quilts. Join can also be used to join surfaces when no
trimming effect is desired.
The following task explains how to Merge and Join surfaces in a part model:
1. Open merge.prt. Select the oval surface.
2. Press CTRL and select the boundary surface.
·F\J
3. Start the Merge Tool from the Feature toolbar.
4. In the dashboard, select the Options tab and select Intersect if necessary.

5. Click Preview Feature i &:f' J.

Fig 3.179: Merged surface

6. Click Resume Feature

�
�- In the dashboard, click Change Second Quilt Side x
7. Click Preview Feature i &5' 1.

Fig 3.180: Merged surface to other side

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8. Click Resume Feature W In the graphics window, click both arrows to flip them.
9. Click Preview Feature i &fl 1.
I'
,\
...

15. Press C

16. Start tt
Fig 3.181: Merged surface flipping both sides 17. In th e c

10. Click Resume Feature

�
L.tJ. In the dashboard, click Change Second Quilt Side x
�
11. Click Complete Feature . .

18. Press C

19. Click C1
Fig 3.182: Merged surface to flipping second side
20. Notice
Join surface in a part model edges.

1 2. Press CTRL and select JOIN1 , JOIN2 and JOIN3. 21. Click SI

13. Right-click and select Unhide. Deselect all geometry and click No hidden Bl
14. Notice the one-sided pink edges between the main surface and the three "joined" surfaces as shown
below.

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Fig 3.183: Surfaces to join

15. Press CTRL and select the main center quilt and right quilt.

16. Start the Merge Tool @ from the Feature toolbar.

17. In the dashboard, select the Options tab and select Join.

Fig 3.184: Surface selected for Join

18. Press CTRL and drag a window around all the quilts to select them.
�
19. Click Complete Feature and deselect all geometry.
20. Notice that the edges between the main surface and the three joined surfaces are two-sided magenta
edges.
21. Click Shading (J

shown

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Fig 3.185: Joined surface

This completes the task. To Oc

� sat
Saddle Shutoff Surfaces gene
A Saddle Shutoff typically requires you to create multiple surfaces to achieve the desired shape. �nen

• Create the surfaces. You •

surfa
• Perform surface manipulations.
can l
• Merge the surfaces to create the final shutoff.
Once
form

The f

1.

2. I

3.

Fig 3.186: Saddle Surface Created Fig 3.187: Face Surfaces Created

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Fig 3.188: Final Saddle Shutoff

To handle a saddle shutoff within the part, you must create the surfaces which represent the shutoff faces.
A saddle shutoff is a bit more challenging than the parting line surface or a face shutoff, because you
generally need several surfaces to form the required shape. Typically, you can create the saddle surface and
then create the face surfaces.
You can extrude or revolve the surfaces or use more advanced geometry creation methods like blended
surfaces, depending upon the desired geometry. You can even copy existing surfaces and paste them. You
can then manipulate these surfaces by extending, trimming and offsetting them if needed.
Once the saddle surface and face surfaces have been created, you must merge the surfaces together to
form the required shape.
The following task explains how to complete the saddle shutoff surface in the mold model:
1. Open saddle-shutoff.mfg. Select the saddle-shutoff_wrk.prt and click View > Display Style >
Wireframe.
2. Click Create Parting Surface CJl .
3. Right-click in the graphics window and select Properties. Edit the Name to SADDLE_SHUTOFF and
press ENTER.

Fig 3.189: Saddle-shutoff.mfg

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4. Start the Extrude Tool 'J
5. Right-click and select Define Internal Sketch.
iS
6. Select datum plane MOLD_RIGHT as the Sketch Plane.
i6
7. In the Sketch dialog box, select Top as the Orientation and click Sketch.

8. Click Hidden line @ . Click Use Edge • select the seven edges and click Close from the Type

dialog box.
9. Click Done Section v

i7.
Fig 3.190: Sketch for Saddle-shutoff

· s.
10. Orient to the Standard Orientation and click Shading '
1 1 . I n the dashboard, edit the depth to Both Sides. Edit the depth to 100 and click Complete Feature
�

19.
Fig 3.191: Extruded surfa� 20.
:1
12. Start the Extrude Tool ':J
13. Right-click and select Define Internal Sketch.

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14. Select datum plane MOLD_FRONT as the Sketch Plane and click Sketch.

15. Click Hidden line @1 . Click References icon and select the right angled silhouette edge.
16. Click Close from the References dialog box.

1e Type

Fig 3.192: Reference for sketch

17. Click Line '- and sketch the line on the angled reference, starting at the horizontal reference and
stopping above the saddle surface.

18. Click Done Section v

Feature

Fig 3.193: Sketch for Saddle Shutoff Surfaces

19. Orient to the Standard Orientation and click Shading 0.

20. In the dashboard, edit the depth to Both Sides. Edit the depth to 100 and click Complete Feature
..,,

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Fig 3.194: Extruded sketch 28.

21. Select the quilt you just extruded and start the Mirror Tool :JIC . 29.

�
22. Select datum plane MOLD_RIGHT and dick Complete Feature from the dashboard.

23. Click Plane Display [O.J to disable their display.

30.

31.

Fig 3.195: Mirrored surface

24. Edit the selection filter to Quilts.

25. Select the saddle quilt, press CTRL and select the right face quilt.

26. Start the Merge Tool 0.

27. In the dashboard, dick Change First Quilt Side � and Change Second Quilt Side X as necessary,

until you get the correct final geometry. Click Complete Feature "1i/'

This

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Fig 3.196: Merging surfaces

28. Select the saddle quilt, press CTRL and select the left face quilt. Start the Merge Tool Q
29. In the dashboard, click Change First Quilt Side X and Change Second Quilt Side ,X as necessary,
�
until you get the correct final geometry. Click Complete Feature

Fig 3.197: Merging surfaces

�
30. Click Apply Changes from the Mold toolbar.
31. Spin the model and inspect the saddle surface as shown below.

'Y·

Fig 3.198: Final Saddle Shutoff surface

This completes the task.

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Creating a Parting Surface Manually 4. Cli<

5. Rig
You can create the parting surface manually in d rcun
&a:� "'� e skirt surface does not provide
6. Sel
the desired shape.
7. Sel
You can use a combination of manual parting surface and �r: s::...� �niques.
To manually create a parting surface:
• Start the Parting Surface tool.
• Create all surface features for a loop.
• Merge the surfaces together.
Sometimes the silhouette curve and skirt surface features do not provia� 10J the desired parting surface
shape. You can create the parting surface manually in these types of ciro.."'lSrances. You may also use a
combination of a skirt surface and manual parting surface for a mold mooc... ""'te skirt surface can be used
for the parting surface in the locations, where the proper geometry has bee cre-ated and a manual parting
surface can be created in areas where the skirt surface does not provide � oesired shape.

To create a parting surface manually, you can click Create Parting Surface � from the Mold toolbar
and then use the various basic and advanced surface creation techniques. Each of the surfaces created
8. Cli
belongs to the parting surface feature. You can also use the various editing and manipulation tools on the
surfaces. 9. Cli

After all surfaces have been created for a given loop area in the mold model, you must use the Merge Tool 10. Cli
GJ to merge the surfaces together before completing the parting surface feature.
The following task explains how to create a manual parting surface in a mold model:
1. Open surface-manual.mfg. Select SILH_CURVE_ 1 from the Model Tree.
2. Notice that there is no loop for the square hole, to the left.

11. Cl

1 2. Cl
Fig 3.199: Model for parting surface

3. Click Create Parting Surface c:!J from the Mold toolbar.

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4. Click Edit > Fill from the main menu.

5. Right-click and select Define Internal Sketch.
uvide
6. Select the surface shown below as the Sketch Plane.
7. Select datum plane MOLD_FRONT as the reference and click Sketch.

1rface
use a
� used
arting

Fig 3.200: Sketching planes

!IOI bar
[jl
reated
8. Click No hidden and select the six silhouette edges as references.
ln the
9. Click Close from the References dialog box.

10. Click Shading CJ

Fig 3.201 : References for sketch

11. Click Line '- and sketch the eight lines.

12. Click Done Section v and orient to the Standard Orientation.

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13. Click Complete Feature

{- ·· c-

_J,;e; ;c<ec«c�-"---- ,
-
I ,.
_.
2(

L H
-v
V'
�
v:

Fig 3.202: Sketch for parting surface

14. Click Edit > Fill.

15. Right-click and select Define Internal Sketch.
16. Select the surface shown as the Sketch Plane. Select datum plane mold_front as the reference and
click Sketch.

21

Fig 3.203: Sketch plane for parting surface

1 7. Select the four edges as references and click Close from the References dialog box.

Fig 3.204: References for sketch

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18. Click Line '\.. and sketch the five lines. Click Center and Ends Arc '.;'\ and sketch the arc as
shown.

19. Click Done Section v and orient to the Standard Orientation.

"'
20. Click Complete Feature

·ce and

Fig 3.205: Sketch for parting surface

21. Click Edit > Fill.

;i
22. Start the Extrude Tool n Right-click and select Define Internal Sketch.
.

23. Click Use Previous and click No hidden BJ

Fig 3.206: References for sketch

n
24. Click References icon - and query-select the two surface edges. Click Close.

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30.
31
Fig 3.207: References for sketch
32
25. Click Line '\.. and sketch the three lines.

26. Click Done Section v and onent to the Standard Orientation.

33.

3 -. .
Fig 3.208: sketch for extrude

27. Click Shading J and zoom in towards the surface.

28. Edit the depth to To Selected and select the first filled surface.

29. Click Complete Feature

�

In

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Fig 3.209: Extruded surface
30. Click Plane Display � to disable their display.
31. Edit the selection filter to Quilts. Select the top flat quilt, press CTRL and select the extruded quilt.

32. Start the Merge Tool 0 from the Feature toolbar. Press CTRL and select the smaller filled surface.

Fig 3.210: Merging surface

,
-.,
33. Click Complete Feature .

-.,,
34. Click Apply Changes from the Mo/dtoolbar.

Fig 3.211: Manual Parting surface

This completes the task.

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Lab Session 3.1 7.

8.
Creating the Shower Head Parting Surface
After successfully completing this exercise, you will be able to: 9.

• Create an automatic parting line using a silhouette curve.

• Create a skirt parting surface by using a silhouette curve as a reference.
In this exercise, you will create an automatic parting line using a silhouette curve in the mold model. You
can then use that silhouette curve as the reference, to create the skirt surface in the model.
Create the silhouette curve parting line:
1. Open shower_head_mold.mfg. Select the SHOWER_HEAD_MOLD_WRK.PRT and click View >
Display Style > Wireframe.
2. In the Model Tree, select SLIDER_LEFT_TAB, press SHIFT and select PLUG_VOL
3. Right-click and select Suppress.

Cr
10

11

12
13
14
Fig 3.212: Mold component with Wireframe mold volume

4. Start the Automatic Parting Line � tool from the Mo/dtoolbar.

5. Click Preview from the Silhouette Curve dialog box.
6. Query-select SHOWER_HEAD_MOLD_REF.PRT, right-click and select Hide.

15

Fig 3.213: Automatic parting line

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7. In the Silhouette Curve dialog box, double-click the Loop Selection.
8. In the Loop Selection dialog box, select loop 2 to select loop 6. Click Exclude to exclude the selected
loops and click OK.
9. Click OK from the Silhouette Curve dialog box.

del. You

View >

Fig 3.214: Silhouette Curve

Create the parting surface

10. In the Model Tree, select SHOWER_HEAD_MOLD_REF.PRT, right-click and select Unhide.

11. Click Create Parting Surface c=i from the Moldtoolbar.

-0-
12. Start the Automatic Parting Surface � tool from the Mold toolbar.
13. Select the silhouette curve and click Done from the menu manager.
14. Click Preview from the Skirt Surface dialog box and notice that the creation of the skirt surface fails.

Fig 3.215: Mold component with Wireframe mold volume with parting line

1 5. In the Skirt Surface dialog box, double-click Extension and click OK from the Warning dialog box.

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16. Notice that the area that cannot be extended is highlighted in red at the front of the reference model
as shown below.

24
Fig 3.216: Parting line highlighted which cannot be extended
25
17. In the Extension Control dialog box, select the Extension Directions tab. 26
18. In the Extension Directions tab, click Add. 27
19. Notice that the front edge vertex of the reference model has default direction arrows pointing in two 28
directions. Select the front edge vertex and click Done from the menu manager as shown.
29

Fig 3.217: Selecting vertex

20. Click Plane Display IO.J to enable their display.

21. Query-select datum plane EXTEND_REF as the extension direction reference.
22. Click Flip > OK from the menu manager.

23. Click Plane Display IO.J to disable their display.

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Fig 3.218: Direction shows both sides front parting line

24. Click OK from the Extension Control dialog box.

25. Click Preview from the Skirt Surface dialog box and click Repaint
26. Notice that the skirt surface is now created.
27. Spin the model and notice that the surface is not smooth.
r in two 28. Also notice that the surface does not extend to the workpiece boundaries.
29. Press CTRL + D to orient to the Standard Orientation.

Fig 3.219: Surface created

30. In the Skirt Surface dialog box, double-click Extension and select the Extension Directions tab.
31. In the Extension Directions tab, dick Add.
32. Click and drag a window around the two left vertices and click Done from the menu manager as
shown.

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36.

37.

38.

Fig 3.220: Query-select in one direction

33. Query-select the left workpiece surface and click OK from the menu manager.

39. '

40.

Rg 3.221: Query-select in left direction

34. In the Extension Control dialog box, click Add and select the rear vertex.
35. Click Done from the menu manager.

41.
42.

43.

Fig 3.222: Query-select vertex

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36. Query-select the rear workpiece surface and click Okay from the menu manager.
37. In the Extension Control dialog box. click Add and drag a window around the two right vertices.
38. Click Done from the menu manager.

Fig 3.223: Query-selecting vertex

39. Select the right workpiece surface and click Okay from the menu manager.
40. Click OK from the Extension Control dialog box.

Fig 3.224: Query-selected all vertex

41. Click Preview from the Skirt Surface dialog box.

42. Spin the model and notice that the surface is now smooth and that it also extends to the workpiece
boundaries.
43. Press CTRL + D to orient to the Standard Orientation.

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Fig 3.225: Created Skirt surface

44. I n the Skirt Surface dialog box, double-dick Shutoff Ext.

45. In the menu manager, dick Boundary > Sketch.
46. Select the top workpiece surface as the sketching plane and click Okay > Default from the menu
manager.
47. Select datum plane MOLD_RIGHT and the top workpiece edge as references and click Close from the
References dialog box.

Fig 3.226: Sketch for Shutoff Ext

48. Click Centerline and sketch a centerline on the vertical reference.

49. Sketch, constrain and dimension the rectangle, as shown below. Click Done Section v

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Fig 3.227: Sketch for Shutoff Ext

50. Press CTRL + D to orient to the Standard Orientation.

51. In the Skirt Surface dialog box, double-click Shutoff Plane.

52. Click Plane Display ID.J to enable their display.

Lab Session 3.2

After successfully completing this exercise, you will be able to:

• Create parting surfaces by using basic surface creation tools.
• Modify surfaces by using various editing tools.
In this exercise, you will use manual surface creation techniques to create parting surfaces in the mouse
mold model.

1. Open Mouse_Manual-Parting-Surface. Click Create Parting Surface p from the Moldtoolbar.

2. Rename the parting surface feature by right-clicking and select Properties. Type MAIN as the Name
of the parting surface and press ENTER.
3. Copy the top three rounded surfaces of the mouse mold. Right-click to query and select the MOUSE_
REF.PRT model in the graphics window.

Fig 3.228: Surface selected for copy

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4. Select the top surface, press CTRL and query-select the two remaining surfaces as shown.

5. Click Copy � and click Paste �

6. Click Complete Feature '¥'
_
7. Click in the graphics window to deselect all features.

Fig 3.229: Surface selected

8. Extend one of the edges of the copied surface by a Right-click to query and select the copied surface
F7 (COPY_1). Select the edge of the surface, as shown. Click Edit > Extend from the main menu.

Fig 3.230: Edge selected for extend

9. I n the dashboard, click Extend Surface To Plane I�l

10. Select the right workpiece surface as the extend plane.

1 1 . Click Complete Feature 'Y'

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Fig 3.231: Extended surface

12. Extend another edge of the copied surface by Spin the model to the orientation as shown. Query­
select the copied surface F7(COP'f_1 ). Select the edge of the surface, as shown. Click Edit > Extend
from the main menu.

Fig 3.232: Edge selected for extend

13. In the dashboard, dick Extend Surface To Plane I;:j]l.

14. Select the left workpiece surface as the extend plane.

15. Click Complete Feature �

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19.
20.

21.

Fig 3.233: Extended surface

16. Extend the third side of the copied surface by pressing CTRL + D to orient the model to the Standard
Orientation. Right-click to query and select the copied surface F7(COPY_ 1 ) . Select the front edge of
the copied surface, as shown.
22

Fig 3.234: Edge selected for extend

1 7. Press SHIFT and select the flat edges of the left and right extended surfaces.

23.

Fig 3.235: Edge selected for extend

18. Click Edit > Extend.

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19. In the dashboard, click Extend Surface To Plane Ic:j]l.
20. Select the front workpiece surface as the extend plane.
..,,,
21. Click Complete Feature

rta ndard
edge of
Fig 3.236: Extended surface

22. Extend the final side of the copied surface by a Right-click to query and select the copied surface
F7(COPY_1). Select the rear edge of the copied surface, as shown.

Fig 3.237: Edge selected for extend

23. Press SHIFT and select the flat edges of the left and right extended surfaces.

Fig 3.238: Edge selected for extend

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24. Click Edit > Extend.

25. In the dashboard, click Extend Surface To Plane ;jJ.

l. (
26. Query-select the rear workpiece surface as the extend plane.
2. J
27. Click Complete Feature � 3. J
.i. )

5.

1.
2.

3. '

Fig 3.239: Extended surface 4.

5.
28. Click Apply Changes � from the Mo/dtoolbar.

Rg 3.240: Parting surface created

This completes the task.

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0 Splitting the Workpiece

0 Splitting Mold Volumes

0 Blanking and Unblanking Mold Items

0 Analyzing Split Classification

0 Mold Component Extraction

0 Mold Features Creation

0 Waterline Circuits

0 Creating Sprues and Runners

0 Ejector Pin Clearance Holes

0 Filling and Opening the Mold

0 Opening the Mold

0 Draft Checking a Mold Opening Step

0 Interference Checking a Mold Opening Step

0 Viewing Mold Information

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4. Creating Mold
Splitting Mold Volumes

After the necessary mold volumes and parting surface have been created, you must split the workpiece
and mold volumes at the parting surface into the final core, cavity and slider volumes, as well as any other
volumes that are to become mold components in the final mold.
You can split the workpiece by using a parting surface or mold volume to create the core and cavity
volumes of the mold model.
Split the workpiece using the All Wrkpcs split option. A new mold volume is created equal to the workpiece
volume i.e. reference model geometry subtracted. The volume is split into one or two volumes i.e. using a
parting surface or other volume.

PULL DIRECTION

Fig 4. 1 : Mold Model and Parting Surface Fig 4.2: Split Mold Model Core Volume

Fig 4.3: Split Mold Model Cavity Volume

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Splitting the Workpiece

You can split or divide the workpiece with the All Wrkpcs split option, by using a parting surface or a mold
volume. When the workpiece split is performed, Pro/ENGINEER calculates the total volume of the workpiece
and creates a mold volume from it. The system then subtracts or trims the reference model geometry and
any mold features such as gates, runners and sprues from the workpiece volume and creates a Refport
Cutout feature in the Model Tree (this Refpart Cutout feature displays in the Model Tree, differently than
a re.kre.m:.e part tutout ope.ration that is performed on a mold '4olume.).

The remaining mold volume is then split at the specified parting surface or mold volume. The system trims
the amount of workpiece volume to one side of the parting surface or mold volume and turns that volume
into its own mold volume. If applicable, the system also trims the amount of workpiece volume on the
other side of the parting surface or mold volume and turns that volume into its own mold volume. A simple
mold model containing only a core and cavity is a typical example. One of the mold volumes becomes the
core and the other the cavity.
One Volume or Two ?

For each split operation, you must determine how many resultant mold volumes are to be created, by
specifying one of the following options:
Two Volumes - Splits the workpiece into two mold volumes.
One Volume - Splits the workpiece into a single mold volume, discarding the other portion. You must
specify which portion you want to include in the mold volume. You can do this using the Island List. The
Island List enables you to select which portion to include in the new volume. When you cursor over ar
island in the list, the corresponding geometry will be highlighted in blue, in the graphics window.
Regardless of how many volumes are created, the system prompts you to name each one. You can determine
the volume to be created, by shading it. The system hides all the other volumes at this time and creates a
mold volume with the name you specify.
The following task explains how to Split a mold model workpiece into volumes:
1. Open split-workpiece.mfg. Select the SPLIT-WORKPIECE_WRK.PRT and click View > Display Style
> Wireframe.

2. Notice the skirt parting surface.

Fig 4.4: Mold component with parting surface

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3. Click Split Mold Volume t;j from the Mo/dtoolbar.
4. Click Two Volumes > All Wrkpcs > Done from the menu manager.
e workpiece
5. Notice that the workpiece has been filled with a mold volume as shown below.
metry and
a Refpart
rently than

me on the
e. A simple
becomes the

created, by Fig 4.5: Mold volume

6. Select the parting surface from the graphics window.

7. Click OK from the Select dialog box.

Fig 4.6: Parting surface

8. Click OK from the Splitdialog box.

9. In the Properties dialog box, click Shade. Notice that the volume will be the core of the mold. Type
CORE_VOL and press ENTER.

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Fig 4.7: Core

10. In the Properties dialog box, click Shade.

11. Orient to the 30 view orientation and notice that this volume will be the cavity of the mold.
12. In the Properties dialog box, type CAVITY_VOL and press ENTER.

Fig 4.8: Cavity

13. Orient to the Standard Orientation.

14. In the Model Tree, notice the Refpart Cutout feature.
1 5. Also notice the two mold volumes that were created and their names.

l"'v' SILH_CURVE_l

� Skirt Surface id 336 (PART_SURF_1 - PARTING SURFACE]

� Refpart Cutout id 426
� Split id 425 (CORE_VOL - MOLD VOLUME]
� Split id 761 [CAVITY_VOL - MOLD VOLUME]
+ Insert Here

Fig 4.9: Model Tree

This completes the task.

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Splitting Mold Volumes
You can also split existing mold volumes to create volumes for sliders, lifters. inserts and so on.
Split mold volumes, using the Mold Volume split option i.e. specifies the volume to be split in the Search
Tool. The specified volume is split into one or two volumes i.e. using a parting surface or other volume.

PULL DIRECTION

Rg 4.10: Mold component and sliders

PULL Oll'lEG.ON

Fig 4.11: Core Volume Before it is split for slider volumes Fig 4.12: Core Volume after splitting slider volumes

Two Volumes - Splits the mold volume into two mold volumes.
One Volume - Splits the mold volume into a single mold volume, "discarding" the other portion. You must
specify which portion you want to include in the mold volume. This is done using the Island List. The Island
list enables you to select which portion to be included in the new volume. When you hover over an island
in the list, the corresponding geometry will be highlighted in blue, in the graphics window.
When you split a volume by a parting surface, the volume is split at the parting surface and either one or
two volumes are created in place of the original volume.
When you split a volume by another volume, the original volumes are not modified. Rather, the original
volumes are copied and then split.

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Creating Intermediate Mold Volumes

Depending on the mold model and its complexity, not every mold volume created will be used to create
a final solid mold component It may be necessary to create ·intermediate" or "temporary" mold volumes :9.
during splitting operations. For example, if you split the workpiece into the core and cavity volumes, the
0.
core volume must further be split to remove a slider volume; you create an intermediate core volume.
The following task explains how to Split the workpiece and mold volumes of a mold model: l .
1. Open split-volumes.mfg. Select the SPLIT-VOLUMES_WRK.PRT and click View > Display Style >
Wireframe.
2. Notice the skirt parting surface and the two slider mold volumes in the graphics window and Model
Tree.

12.
fig 4.13: Mold component and parting surface
13.
l•
-.

3. Click Split Mold Volume @ from the Mold toolbar. · s.

4. Click Two Volumes > All Wrkpcs > Done from the menu manager.
5. Notice that the workpiece has been filled with a mold volume.
6. Select the parting surface from the graphics window and click OK from the Select dialog box.

Fig 4.14: Mold volume and parting surface

16.

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Click OK from the Split dialog box.
In the Properties dialog box, click Shade.

Click Wireframe �.
Notice that the volume will be the core of the mold, but it has not taken the slider volumes into
account.
In the Properties dialog box type TEMP-CORE_VOL1 and press ENTER.

Fig 4.15: Core in Wircframc

12. In the Properties dialog box, click Shade.

13. Spin the model and notice that this volume will be the cavity of the mold.
14. In the Properties dialog box, type CAVITY_VOL and press ENTER.
15. Orient to the Standard Orientation.

Fig 4.16: Splitcd Cavity

16. In the Model Tree, right-click CAVITY_VOL and select Hide.

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17. Click Split Mold Volume tj and click One Volume > Mold Volume > Done from the menu
manager.

18. In the Search Tool, select the TEMP-CORE_VOLl quilt and click Add Item � and then click Close.
19. Query-select the front slider volume and click OK from the Select dialog box.

23.

2-i.
25.

Fig 4.17: Slider is selected for splitting

20. In the menu manager, select the Island 1 check box and click Done Sel.
21. Click OK from the Split dialog box.

26.
21.

Rg 4.18: Slider selected for splitting

22. In the Properties dialog box, click Shade and notice that the slider volume has been trimmed from the
temporary core volume. Type TEMP-CORE_VOL2 and press ENTER.

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the menu

click Close.

Fig 4.19: Core without slider

23. Click Split Mold Volume � and click One Volume > Mold Volume > Done.

24. In the Search Tool, select the TEMP-CORE_VOL2 quilt and click Add Item 8 and click Close.
25. Query-select the rear slider volume and click OK from the Select dialog box.

Fig 4.20: Core, component and 2nd slider

26. In the menu manager, select the Island 1 check box and click Done Sel.
27. Click OK from the Splitdialog box.

ed from the

Fig 4.21: Selected 2nd slider to split

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28. In the Properties dialog box, click Shade and notice that the slider volume has been trimmed from the
final core volume. Type CORE_VOL and press ENTER.

2
Fig 4.22: Splited two sliders from core

\his completes the tasl<.. 3

4
Splitting Volumes using Multiple Parting Surfaces
5
You can use multiple parting surfaces to split a workpiece or mold volume.
• You can use multiple parting surfaces in a single split operation.
• You can use multiple parting surfaces in multiple split operations.
You can use multiple parting surfaces to split volumes in two different ways:
• You can use multiple parting surfaces to split a workpiece or mold volume into multiple mold volumes.
You can use one parting surface for one split operation and specify a different parting surface for a
second split operation. Of course you must also specify the workpiece or mold volume to split and the
names of the first and, if applicable, second volumes.
• Sometimes the shape of the reference model and the parting surfaces created require that, you specify
more than one parting surface during a single split operation. In these circumstances, you can press
a\\\.\n l:)�Ut� \I) ')t\tt\ mu\\\?\t ?o�\\n9 wnott'). 'i°l:>U t'OT'I a\c:,I:) C:,t\tt\ mu\\\'\)\t mtM %\umts \o S?\\\ a
workpiece or mold volume in a split operation

Q fwt.I..T-Sl.Rf2.ASM
+ Qfwt.l..T-Sl.Rf2_REF.PRT
+ 9fwt.l..T-Sl.Rf2_WRK.PRT
+ (}l Extrude 1 [MAIN_PART_Sl.Rf - PARTING SLRFACf]
+ � Extrude 2 [SJDE_PART_Sl.Rf - PARTING SlRFACE]
� Copy 1 [SJDE_pART_SLRf - PARTING SLRFACf]
� Merge l [SJDE_pART_SLRf - PARTINGSLRFACf]
-+ lnsl:«�
Fig 4.23: Model Tree containing multiple Parting Surfaces

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Fig 4.24: Multiple Parting Surfaces

The following task explains how to Split mold volumes using multiple parting surfaces:
1. Open mult-surf1.mfg. Select the MULT-SURF1_WRK.PRT and click View > Display Style >

Wireframe.
2. Notice that there are two parting surfaces, SKIRT_PART-SURF and MANUAL_PART-SURF.

3. Click Split Mold Volume @ from the Mold toolbar.

4. Click Two Volumes > All Wrkpcs > Done from the menu manager.
5. Press CTRL, select the two parting surfaces and click OK from the 5e/ectdialog box.

PULL DIRECTION

lumes.

n press
split a
Fig 4.25: Mold volume with parting surface

6. Click OK from the Split dialog box.

7. In the Properties dialog box, click Shade, type CORE_VOL and press ENTER.

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Fig 4.26: Splited Core

8. In the Properties dialog box, click Shade, type CAVITY_VOL and press ENTER.
1 6.

Fig 4.27: Splited Cavity

Split volumes with multiple parting surfaces in two split operations.

9. Open mult-surf2.mfg.
17.
10. Select the MULT-SURF2_WRK.PRT and click View > Display Style > Wireframe.
1 1 . Notice the two parting surfaces, MAIN_PART_SURF and SIDE_PART_SURF.

12. Click Split Mold Volume t;j .

13. Click Two Volumes > All Wrkpcs > Done from the menu manager.
14. Select the SIDE_PART_SURF and click OK from the 5e/ectdialog box.

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Fig 4.28: Multiple Parting surface with mold volume

15. Click OK from the Splitdialog box.

16. In the Properties dialog box, click Shade, type TEMP-MOLD_VOL and press ENTER.

Fig 4.29: Splited multiple parting surface mold volume

17. In the Properties dialog box, click Shade, type SLIDER_VOL and press ENTER.

Fig 4.30: Core splited from mold volume

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18. Click Split Mold Volume @ and click Two Volumes > Mold Volume > Done.

19. In the Search Tool dialog box, select TEMP-MOLD_VOL. click Add Item � and click Close.
20. Query-select the MAIN_PART_SURF and click OK from the Select dialog box.

Fig 4.3 1 : Selected Second Parting Surface

1
21. Click OK from the Split dialog box. c

22. In the Properties dialog box, click Shade, type CORE_VOL and press ENTER. l

"r

Fig 4.32: Splited volumel

23. In the Properties dialog box, click Shade, type CAVITY_VOL and press ENTER.

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Fig 4.33: Splited volume2

This completes the task.

Blanking and Unblanking Mold Items

The Blank and Unbfank options enable you to add or remove mold items to the current mold model
display.
Use these options at any time, while in Mold mode.
You can blank and unblank the following:

• Parting Surface p

• Volume ell

• Component 0
Use the following methods:
• Blank-Unblank Dialog Box
• Right-dick after item selection.

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Fig 4.34: Blank-Unblank Dialog Boxes

The following items can be blanked and unblanked:

• Parting Surface p - Enables you to blank/unblank any parting surface in the mold model.

• Volume Eal - Enables you to blank/unblank any mold volume, such as sliders, cores and cavities.

• Component 0 - Enables you to blank/unblank the reference model, workpiece or any other mold
component.
You can blank and unblank mold items using the following methods:

Click Blank/Unblank � to access the Blank-Unblank dialog box. The Filter Tree in the dialog box enables
you to see only the mold item types that you want to blank or unblank. You can filter by parting surfaces,

volumes or components. If you click Parting Surface p , for example, you will see only the parting
surfaces available for selection in the dialog box. The following component items can further be filtered:
• Workpiece
• Ref Model
• Mold Component
• Mold Base Comp
• Gen Assembly
• Molding
The Blank-Unblank dialog box contains a Blank and Unblank tab. Items listed in the Blank tab are those
that are visible in the graphics window but available only for blanking. If you select an item and click
Blank, the item is moved to the Unblank tab of the dialog box.

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Similarly, the Unblank tab displays all items that are blanked in the graphics window.
• Select items from the Model Tree, right-click and select Blank or Unblank. If the mold item s
comprised of numerous features, which can occur for a mold volume or manually created parting
surfaces, you must select the first feature to blank or unblank the item. The Blank and Unblank menu
selection is only available for the first feature of the mold item.
• Select items from the graphics window, right-click and select Blank or Unblank.
The following task explains how to Blank and Unblank mold items using the Blank-Unblank dialog box:

1. Open blank-unblank.mfg. Click Blank/Unblank � from the Main toolbar.

2. In the Blank-Unblank dialog box, select Component 0 as the Filter, if necessary. Press CTRL and
select BLANK-UNBLANK_REF and BLANK-UNBLANK_WRK. Click Blank.

Fig 4.35: Mold volume

3. In the Blank-Unblank dialog box, select Volume eal as the Filter. Select CAVITY_VOL a,..d
Blank.

Fig 4.36: Blanked one slider

4. In the Blank-Unblankdialog box, select CORE_VOL and click Blank.

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Fig 4.37: Blanked another slider

5. I n the Blank-Unblankdialog box, select Parting Surface c::i as the Filter. Select MAIN_PART_SURF
and click Bla n k.

Fig 4.38: Blanked parting surface

6. Inthe Blank-Unblank dialog box, select the Unblanktab. Select Component () as the Filter. Select
BLANK-UNBLANK_REF and click Unblank. Click Close.

Rg 4.39: Unblanked mold component

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Blank and Unblank mold items from the model tree and graphics window.
7. In the Model Tree, right-click SLIDER_VOL and select Blank.

8. Click Repaint (L] and deselect all geometry.

i�;1'
�
i

.... ;�.
SURF
···-·<1$�

Fig 4.40: Mold component and partin g surface

9. From the graphics window, select the side parting surface, right-click and select Blank. Click Repaint
[L]

ielect

Fig 4.41 : Mold component

10. In the Model Tree, right-click CORE_VOL and select Unblank.

11. Click Repaint GJ and deselect all geometry.

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W I L D F I R E
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Fig 4.42: Mold component and unblanked core volume

12. In the Model Tree, right-click BLANK-UNBLANK_REF.PRT and select Blank.

Fig 4.43: Mold component blanked

This completes the task. WI

an
Analyzing Split Classification en
th•
The process of determining which individual closed islands of space should be included in the resultant up
mold volume is called Classifying.
Ea1
• An island is a closed volume of space in the mold model. mt.
Thi
•
Specify the islands to be included i n the resultant volume.
• Classifying islands enables you to create simpler manual parting surfaces. Oc

A(
res
anc
mu
vol

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Fig 4.44: Viewing Reference Part Geometry

Fig 4.45: Classifying Islands Fig 4.46: Resultant Mold Volume

When you split a volume, depending upon the shape of the workpiece, the shape of the reference model
and the shape of the parting surface, the split may create several individual closed volumes. When you
create a split using the Two Volumes option, each of these volumes must end up as part of one volume or
the other. Similarly, when you create a split using the One Volume option, each of these volumes must end
up as part of the new volume or are left to remain in the old volume.
Each one of these individual closed volumes occupies an island of space within the mold model. You
must specify which islands of space should belong together or be included, in the resultant mold volume.
The process of determining which islands should be included in the resultant mold volume is callee
Classifying.
A One Volume split always creates a situation where you must classify the islands to be included in the
resultant volume. The reason for this is that regardless of whether you split by a parting surface or ::.
another volume, you must specify which side of the split you want to include in the resultant volume. "'o­
must also classify islands, when you specify multiple parting surfaces or mold volumes when sp � · '":; •
volume.
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Fig 4.47: Parting surface

The following task explains how to classify islands to split mold volumes correctly:
1. Open split-classification.mfg. Select the SPLIT-CLASSIFICATION_WRK.PRT and dick View > Display
Style > Wireframe.
2. Notice the three cuts along the side of the reference model.
3. In the Model Tree, right-click SLIDER_PARTING-SURF and select Unblank.

Fig 4.48: Mold component

4. Click Split Mold Volume � from the Mold toolbar.

5. Click Two Volumes > All Wrkpcs > Done from the menu manager.
6. Select the parting surface from the graphics window.

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Fig 4.49: Mold volume and parting surface

7. Click OK from the 5e/ect dialog box.

8. In the menu manager, cursor over Island 1 and notice the corresponding space the island occupies, is
highlighted in blue. Select the Island 1 check box.
play

Fig 4.50: Mold volume divided into two volumes

9. In the menu manager, select the Island 3, Island 4 and Island 5 check boxes. Click Done Set.
10. Click OK from the Split dialog box.
11. In the Properties dialog box, click Shade and spin the model to inspect the mold volume. Type SLIDER_
VOL and press ENTER.

Fig 4.51: Splited Slider

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12. Orient to the Standard Orientation.

13. In the Properties dialog box, click Shade, type TEMP-MOLD_VOL and press ENTER.

22.

Fig 4.52: Shaded mold volume 23.

14. Click Split Mold Volume @ from the Mo/dtoolbar.

Click Two Volumes > Mold Volume Done.
D
15. >

16. In the Search Tool, select the TEMP-MOLD_VOL qui lt and click Add Item � and then click Close.
17. In the Model Tree, right-click core-cavity_parting-surf and select Unblank.
18. Query-s�lect the parting surface and click OK from the Select dialog box.

This

Mo

Onct
Fig 4.53: Mold volume and parting surface can
and
19. In the menu manager, select the Island 1, Island 3 and Island 4 check boxes and click Done Sel.
In th
20. Click OK from the Split dialog box.
21. In the Properties dialog box, click Shade and spin the model to inspect the mold volume. Type CAVITY_
VOL and press ENTER. You

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Fig 4.54: Splited Core

22. Orient to the Standard Orientation.

23. In the Properties dialog box, click Shade, type CORE_VOL and press ENTER.

fose.

Fig 4.55: Spllted Cavity

This completes the task.

Mold Component Extraction

Once the proper mold volumes have been created and split, you can now create the mold components. You
can create mold components by filling the mold volumes with material. This process is called extracting
and it automatically converts the mold volumes into fully functional solid parts.
ti.
In this module, you will learn how to extract the final solid mold components from mold volumes.

ITY_ Extracting Mold Components from Volumes

You can produce mold components by filling the previously defined mold volumes with solid material.

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Mold component features: l

• Contain an Extract feature. (

• Are fully-functional parts.

• Maintain a parent/child relationship with their mold volumes. \

Mold component color-coding: l

f
• Reference model color
a
• Blu e c
• Yellow c
\J

E
n
v
n

8
tJ
•

Rg 4.56: Extracted Core Mold Component •

1.

Fig 4.57: Extracted Cavity Mold Component Fig 4.58: Extracted Slider Mold Component

Once the mold volumes are created and the workpiece and mold volumes are split, you can create the final
mold components. You can produce mold components by filling the previously defined mold volumes with
solid material. This process, performed using the Create Cavity Inserts e option, is called extracting.
Extracted parts can be core and cavity pieces as well as sliders, inserts, core pins and so on.

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The system does not automatically create mold components from every mold volume, found in the mold
model. Recall that you may have created temporary mold volumes during the split process in order to
create your desired mold volumes. Consequently, you must specify which mold volumes will be extracted
into the mold components. When the mold components are extracted and created, the corresponding mold
volumes are automatically blanked from the graphics window.
The extracted mold components are created in the mold model and each component contains an Extract
feature that contains the solid geometry. The extract feature cannot be redefined, but these components
are fully functional parts. You can retrieve them in Part mode and add new features to them. To save the
extracted mold components, you must save the mold model before erasing it from memory or exiting your
current Pro/ENGINEER session. By default, the extracted mold components are named the same as the
volumes from which they were extracted.
Extracted mold components maintain a parent/child relationship with their mold volumes. Therefore, the
mold components automatically update when changes are made to the mold volumes. While the mold
volumes are assembly features in the mold model, the mold components are assembly components in the
mold model.
Color-Coding of Extracted Mold Components
By default, the extracted mold components are created in the default Pro/ENGINEER gray color. However,
the surfaces of the extracted mold components may also display in three other potential colors:
• Reference model color - The mold components surfaces that touch the reference model are color­
coded, the same as the reference model..
• Blue - Steel-to-steel contact between tooling component shutoffs.
• Yellow - Steel-to-steel contact between slider mold component surfaces and mold plates, cores or
cavities. It is important to note that only the slider mold volumes created by calculating undercut
boundaries becomes yellow, when the mold components are extracted. Sketched sliders and other
components will have blue surfaces at their steel-to-steel contact points.
The following task explains how to Extract mold components from mold volumes:

1. Open extract-volumes.mfg. Click No hidden BJ and notice that the mold volumes are surfaces.

Fig 4.59: Mold volume in wireframe

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2. Click Shading CJ
3. Click Create Cavity Inserts e from the Mold toolbar.
4. In the Create Mold Component dialog box, dick Select All \ 1i\. Press CTRL and dick TEMP-MOLD_
VOL 1 to deselect it.

-' Create Mold Component

�=-- - -
�- -- - - -
-
-
�--: :- -'

� _ : ::_: - -·

�TEMP.WOLD_VOL1

Fig 4.60: Crute mold component window

5. Click OK from the Create Mold Component dialog box.

6. Notice the four new mold components created in the Model Tree.

• �CAvrTY_\IOl.PRT
+ �CORE_\IOl.PR.T
+ �SUDER_YOll.PRT
+ �SUDER_YOl.2.PRT

Fig 4.61: Model Trtt Volume parts

7. Click No hidden [j) and notice that the mold components are solid geometry.

8. Click Shading CJ

Fig 4.62: Mold component highlighted

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9. In the Model Tree, right-click CORE_VOLPRT and select Open. Notice the single Extract feature ·n
the model tree.
10. Spin the model to inspect it and notice the surfaces that are in blue. Also notice the surfaces that are
in yellow.
-MOLD_
11. Notice the surfaces that are in reference model color. Click Close Window rE:J to return to the mold
model.

Fig 4.63: Extracted core with colors

12. In the Model Tree, right-click CAVITY_VOLPRT and select Open. Again, notice the single Extract
feature in the model tree.
13. Spin the model to inspect it and again notice the surfaces that are in blue. Notice the surfaces that
are in reference model color.
14. Click Close Window rE:J to return to the mold model.

Fig 4.64: Extracted cavity with colors

This completes the task.

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Mold Features Creation

You can create assembly-level features in a mold model for the purpose of removing material. M0:�
features include waterlines, runners, ejector pin clearance holes and gates. You can use user-definu:
features (UDFs) to define and place waterlines, runners and gates. You can also run a waterlines check fi:r
clearance of waterline circuits in the mold model.
Creating Waterline Circuits
Waterlines are assembly-level features that you can use to create water channels or circuits in the mold
model. Waterlines are drilled holes in the mold model components. The waterline circuits convey coolin;
water through the mold components to control the cooling of molten material. The speed of cooling tht
mold is dire.ct!'( re.late.d to the. \lfO'fitabll\tf ot the. e.nfae. m<lld ?f<ldu<:.t l\ne..
To create a waterline circuit, you must specify the following:
Name - Determines the name of the waterline as it displays in the Model Tree. You can accept the default
name if desired.
Diameter - Enables you to specify the diameter of the waterline hole. You can either type a value or

accept the default diameter value.

Circuit - Enables you to sketch the waterline circuit path. You must specify the sketch plane and referen�
plane and orientation. The sketched section should only contain linear entities. This is because the waterline
path is ultimately drilled into the mold components. As you sketch the circuit in Sketcher, a dashed line
displays on either side of the sketch line. This dashed line denotes the actual section diameter of the
circuit.
Intersected Parts - Enables you to select the mold components that the waterline circuit will intersect
The following options are available for determining which components are going to be intersected or cut.
by the waterline:
• Auto Update lntrscts - When this check box is seleded, the system automatically determines which
mold components will be cut by the waterline feature. All other selection options become grayed out
When this option is used, the automatic intersection excludes the reference models and any kind of
m�\�\\\l;J.
• Select a component to intersect - Enables you to manually specify which components that will tJe
cut by the waterline feature.
• AutoAdd - Similar to the Auto Update lntrscts check box, when this option is selected, the �
automatically determines which mold components will be cut by the waterline feature.
• Info - Enables you to display information regarding the Waterlines feature i n the browser.

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!liold
;ned
k for

11old
Jling
phe Fig 4.65: Completed Waterline Fig 4.66: Cutaway of Waterline Circuit

The following task explains how to create a basic waterline circuit in a mold model:
1. Open waterlines.mfg. Click Insert > Water Line from the main menu.
2. Type 8 as the diameterof the waterline circuit and press ENTER.
3. Select datum plane WLINE as the waterline sketching plane and click Default from the menu
Je or manager.

�.. .r.e

I lir.e

PULL DI RECTIO

1,tiicr
j our. Fig 4.67: Sketch plane
nd o: ..:�
... .
4. Click References icon and select the bottom of the mold component and click Close.

·11 be

PUl L Dlf�ECTIO

Fig 4.68: References to create sketch

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5. Click Line '\. and sketch the three lines.

6.
...;'
Edit the dimensions, as shown below. Click Done Section

I I
''''"''

Fig 4.69: Sketch for waterline

7. Orient to the Standard Orientation.

8. Click Plane Display [O.J to disable their display.

9. In the Intersected Comps dialog box, select the Auto Update lntrscts check box. Click OK.
10. Click OK from the Water line dialog box.
11. Notice the waterline feature in the Model Tree.

Fig 4.70: Water line

12. In the Model Tree, right-click CUT and select Resume.

13. Deselect all geometry and zoom in on the waterline.

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Fig 4.71: Sectional view of Water line

10��
14. Right-click WATERLINE_ 1 and select Edit.
1 5. Edit the diameter value from 8 to 1 0 and click Regenerate S= .

Fig 4.72: Editing Water line dimension

16. Right-click WLINE_CAVITY.PRT and select Open.

17. Notice the assembly cuts in the Model Tree.
18. Click Close Window rEJ.

Fig 4.73: Final Water line

This completes the task.

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Analyzing Waterline End Conditions The

You can apply optional end conditions to the waterline circuit segment endpoints. You can apply end 1.
conditions to ensure that the circuit is capable of being manufactured. You can apply the following end 2.
conditions: 3.
None - Causes a standard, blind end to be created on the end. By default. each waterline circuit end, has
this option specified.
Blind - Enables you to specify an extra drilled blind end. You can extend the drilled end, a specified
distance beyond the endpoint.
Thru - Enables you to create a straight hole end condition. The system extends the drilled end out through
all mold model geometry.
Thru w/Cbore - Enables you to create a counterbore hole end condition. Similar to the Thru option, the
system extends the drilled end out through all mold model geometry. However, the system also places a
counterbore at the entrance of the mold geometry. You can specify both the counterbore diameter and
depth.

4. "
5. T
6. 1'

Fig 4.74: Blind Waterline End Condition Fig 4.75: Thru w/Cbore Waterline End Condition

Fig 4.76: Thru Waterline End Condition

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The following task explains how to add various end conditions to a waterline in a mold model.
1. Open end-conditions.mfg. Edit the definition of WATERLINE_ 1 .
r end
!I end 2. In the Water Line dialog box, double-click End Condition.
3. Select the front, left waterline segment and click OK from the Se/ectdialog box.
has

ified

Fig 4.77: End selected for W/Cbore

4. In the menu manager, click Thru w/Cbore > Done/Return.

5. Type 1 2 for the Counterbore diameter and press ENTER.
6. Type 1 5 for the Counterbore depth and press ENTER.

Fig 4.78: W/Cbore to water line

7. Select the left side of the rear waterline segment and click OK from the Select dialog box.

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Fig 4.79: Line selected for blind hole

8. In the menu manager, click Blind > Done/Return.

9. Type 8 as the value, to extend the left side and press ENTER.

Fig 4.80: Blind hole created

10. Select the right side of the rear waterline segment and click OK from the Select dialog box.

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Fig 4.81: Line selected for thru hole

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11. In the menu manager, click Thru > Done/Return.

Fig 4.82: Water line creating thru hole

12. Click Done/Return from the menu manager.

13. Click OK from the Water Line dialog box.
14. In the Model Tree, right-click CUT and select Resume.
15. Deselect all geometry.
16. Spin the model and inspect the waterline.

Rg 4.83: Final water lints

This completes the task.

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Performing a Waterlines Check

You can perform a clearance check for waterline circuits by selecting the Waterlines option from the
analysis Type drop-down list in the Mold Analysis dialog box. The waterlines check helps to ensure that the
waterlines are not too close to the external surfaces of the mold model. To perform the waterlines check,
you must specify the following:
Part - Enables you to specify the part, whose external surfaces are used for measuring the minimum
clearance. You cannot specify the reference model as the part.
Waterline - Enables you to specify which waterlines to analyze. Options include:
• All Waterlines - All waterlines in the mold model are analyzed.
• Select Waterlines - Enables you to specify which waterlines are analyzed.
• Select Surfaces - Enables you to specify a surface of the mold component to be analyzed against the
waterlines and the other external surfaces of the mold component.
Minimum Clearance - Enables you to specify the minimum clearance that the waterlines must be from
the external surfaces of the specified part.
Understanding Waterlines Check Results
The results of the waterlines check are color-coded into two categories:
• Magenta - All areas of the waterlines highlighted in magenta are less than the minimum clearance
specified.
• Green - All areas of the waterlines highlighted i n green are greater than or qual to the minimum
clearance specified.

Fig 4.84: Waterlines Check Results Fig 4.85: Waterlines within Minimum Clearance

The following task explains how to perform a waterlines check on waterline circuits in a mold model:
1. Open waterlines-check.mfg. Press CTRL and select wline-check_cavity.prt and wline-check_slider.
prt. Click View > Display Style > Transparent from the main menu.

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It the

eek,

mum

151: the
Fig 4.86: Mold vo l u me with water l i nes

e from
3. C l i c k Ana lysi s > M o l d Ana lys i s from the m a i n m e n u .

4. I n the M old Analysi s d ia l og box, sel ect Waterl i n es from the Type d rop-down l ist, if n ecessa ry. Click

Sel ect Part a n d select w l i ne-check_cavity. prt.Type 8 as the Minimum Clearance and p ress
ENTER.
arance
5. Click Compute a n d then c l i c k Repa int [21 .
imum 6. N otice that, o n l y the o uter ends of the waterl i n e c i rc u i t fa l l i ns i d e of the m i n i m u m cleara nce
s pecified.

PULL DI RECTION

� el •

_sl ider. 7.
Fig 4.87: Col o r difference Clearance of water l i ne

I n the Mold Analysis dia l og box, edit the M in i mum Clea rance to 10 and cl ick Com p ute.

8. N otice that o n ly the cou nterbore fa l ls w i t h i n the m i n i m u m c l ea ra nce specified.

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Fig 4.88: Analyzed water line

9. In the Mold Analysis dialog box, click Select Part W and select WLINE-CHECK_SLIDER.PRT. Edit
the Minimum Clearance to 6 and click Compute.

10. Click Repaint CLl .

1 1 . Notice that. i t appears as the waterline circuit is properly designed.

Fig 4.89: Properly designed water lines

12. Zoom in, on the waterlines circuit and spin the model.
13. Notice that the waterlines circuit is too close to the inner surface of the mold component.
14. Click Close from the Mold Analysis dialog box.

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Fig 4.90: Analyzed water line show closer

Edit 1 5. Orient to the WLINES view orientation.

16. In the Model Tree, right-click waterline_slider and select Edit.
a��
17. Edit the waterline circuit diameter to 6 and click Regenerate g

Fig 4.91: Regenerated water line

18. Click Analysis > Mold Analysis. Click Select Part (!] and select WUNE-CHECK_SLIDER.PRT.
19. Edit the Minimum Clearance to 6 and click Compute.

20. Click Repaint [L] .

21. Zoom in, on the waterline and spin the model.
22. Notice that the waterline circuit now properly falls outside the minimum clearance specified.
23. Click Close from the Mold Analysis dialog box.
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Fig 4.92: Analyzed water line without any problem

This completes the task.

Creating Sprues and Runners

Creating Sprues
A sprue is the channel through which molten plastic is injected into the mold. The sprue should be as short
as possible to minimize the material usage. Typically, the sprue is tapered, to ensure proper ejection from
the mold cavity.
You can create sprues in the mold model using sketch-based features such as extrudes, revolve, sweeps
and blends.
Creating Runners and Gates
You can create runners and gates in the mold model to transfer material from the sprue to the mold cavity.
The runner is the channel that guides the molten plastic from the sprue into the mold cavity, and the gate
is the restricted entrance, from the runner into the mold cavity that helps to simplify the removal of the
final molded parts from the runners.
You can use the Runner feature to create the runners in your mold model. Depending upon the shape of
your gates, you can also use the runner feature to create them or you can create them using sketch-based
features such as extrudes, revolves, sweeps and blends.
You can create runners by sweeping a sketched section along a path or trajectory. The following section
shapes are available and the dimensions that define the shapes are shown below:
Round - Assigns a circle, to the runner's cross-section.
Half Round - Assigns a half circle, to the runner's cross-section.
Hexagon - Assigns a six-sided polygon, to the runner's cross-section.
Trapezoid - Assigns a quadrilateral, to the runner's cross-section.
Round Trapezoid - Assigns a trapezoid with an arc base, to the runner's cross-section.

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Round - Assigns a circle, to the runner's cross-section.
¢ 12

Half Round - Assigns a half circle, to the runner's cross-section.

Hexagon - Assigns a six-sided polygon, to the runner's cross-section.

ort
om
Trapezoid - Assigns a quadrilateral, to the runner's cross-5'ction.

eps

Round Trapezoid - Assigns a trapezoid with an arc base, to the runner's cross-section.

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In addition to the shape, you must define the following items:

• Name - Enables you to specify the name of the Runner feature in the Model Tree to be different than
the default name applied by the system.
• Def Size - Enables you to specify the default size values for each of the runner cross-section
dimensions. The dimensions that you are prompted to specify depend on the section shape specified.
• Flow Path - Enables you to either select or sketch the flow path for the runner. If you select the flow
path, you can select datum cu rves as the flow path. If you sketch the flow path, you must specify the
sketch plane, reference plane and orientation. As you sketch the flow path in Sketcher, a dashed line
displays on either side of the sketch line. This dashed line denotes the actual section diameter of the
runner.
• Direction - Specifies the direction of runner creation.
• lntsct Parts - Enables you to select the mold components, which the runner will intersect or cut
through. The same options which are available in the Intersected Components dialog box for waterlines
and ejector pin holes are also available for runners.
Optionally, the Segment Sizes option enables you to define runners with segments of varying size within
the same runner feature. When you specify a runner segment that you want to be of different size than
the default size, the system prompts you to specify new dimensions to define the cross-section. Note that
the runner shape specified cannot be changed for individual segments.
You can create sprues and runners any time after the workpiece and reference model are assembled. When
the volumes are split, any previously-created sprues, runners and gates are automatically subtracted from
the mold volumes along with the reference model

Fig 4.93: Cavity Showing Sprue, Runners and Gates Fig 4.94: Core Showing Runners and Gates

The following task explains how to create the main runner:

1. Open sprue-runner.mfg. Select PUCK_CAVITY.PRT and click View > Display Style > Transparent.
2. Notice the 4 cavity mold model.
3. Select the SPRUE feature already created in the mold model.

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e
e
e

Fig 4.95: Mold volume with sprue

LJt
es 4. Click Insert > Runner from the main menu.
5. Click Hexagon from the menu manager.
1�n 6. Type 10 as the runner width and press ENTER.
an 7. Select datum plane MAIN_pARTING_PLN as the sketching plane and click Okay > Default from the
at menu manager.

en 8. Click Centerline and sketch a centerline on the horizontal reference.

tm 9. Sketch and dimension the line, as shown in the below figure.

10. Click Done Section v

Fig 4.96: Sketch for runner

11. Orient to the Standard Orientation.

12. Press CTRL. select the PUCK_CAVITY.PRT and PUCK_CORE.PRT and then click OK from the 1n�<Se�t-c
Comps dialog box.
13. In the Runner dialog box, double-click Name, edit the Name to MAIN_RUNNER aro o'OS 3fitt
Click OK.
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Fig 4.97: Runner created

Create the secondary runners and gates.

14. Click Insert > Runner and click Round from the menu manager.
15. Type 4 as the runner diameter and press ENTER.
16. Click Use Prev > Okay from the menu manager.
n
17. Click References icon - ....- and query-select datum plane front of the upper-right reference model as
well as its left edge. Click Close.

Fig 4.98: Sketch plane for second runner 2

2
18. Click Centerline and sketch a centerline on both the vertical and original horizontal references.
19. Sketch and dimension the line, as shown below.

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Fig 4.99: Sketch for second runner

20. Sketch and dimension the two smaller lines, as shown.

elas

Fig 4.100: Sketch for runner

21 . Drag a window around the three lines.

22. Click Mirror Oi� and select the horizontal centerline.

23. Click Done Section v .

24. Orient to the Standard Orientation.

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Fig 4.101: Sketch both sides

25. Press CTRL, select the PUCK_CAVITY.PRT and PUCK_CORE.PRT and then click OK from the Intersected
Comps dialog box.
26. Click Repaint CLI .
27. I n the Runner dialog box, double-click Name, edit the Name to SECONDARY_RUNNER and press
ENTER. Click Preview.

Fig 4.102: Runners created

28. In the Runnerdialog box, double-click Segment Sizes .

29. Press CTRL, select the four smaller segments and click Done/Return from the menu manager. Type 2
as the runner segment diameter and press ENTER. Click Done.

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Fig 4.103: Selected Gates

30. Click OK from the Runner dialog box.

md oress

Fig 4.104: Gates are attached to runner

31. In the Model Tree, right-dick PUCK_CAVITY.PRT and select Open.

32. Spin the model and observe the sprue, runners and gates.

Fig 4.105: Runners and gates

-his completes the task.

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Creating Ejector Pin Clearance Holes

Ejector pin clearance holes are created in the mold components so that ejector pins can pass through and
push the molded part out. An ejector pin clearance hole is very similar to the conventional hole feature
except that you can specify a different diameter through each component that the hole intersects in the
mold model. An ejector pin hole is created as an assembly feature in the mold model.
You can create the following types of ejector pin clearance holes:
Linear - Enables you to create an ejector pin hole on a selected reference, offset linearly from two
references.
Radial - Enables you to create an ejector pin hole on a selected reference, at a radial offset from an axis
and at an angle from a plane. When you specify a radial hole type and select the axis, you can specify the
radial offset in the following ways:
• Diameter - Places the hole with a diameter dimension for the offset.
• Radius - Places the hole with a radius dimension for the offset.
• Linear - Places the hole with a linear dimension for the offset.
Coaxial - Enables you to create an ejector pin hole on a selected reference, through a selected datum axis.
If the ejector pins are already assembled in the mold model, then you can use the coaxial hole to easily
place the ejector pin clearance holes. You can also use the axes created for the ejector pin pads created in
the reference model.
On Point - Enables you to create an ejector pin hole through a specified datum point. If there are several
datum points in the mold model where the holes should be placed, you can simultaneously place holes at
each point within the same hole feature.
Once the ejector pin hole type and placement references have been defined, you must specify the following
options:
Direction - Determines the direction of hole creation. You can also flip the direction.
Intersected Parts - Enables you to select the mold components that the ejector clearance hole will
intersect. The following options are available for determining which components are going to be intersected
or cut, by the ejector pin:
• Auto Update lntrscts - When this check box is selected, the system automatically determines "."hich
mold components will be cut by the ejector pin hole feature. All other selection options become
grayed out. When this option is used, the automatic intersection excludes the reference models and
any molding.
• Select a component to intersect - Enables you to manually specify which components will be cut by
the ejector pin hole feature.
• AutoAdd - Similar to the Auto Update lntrscts check box, when this option is selected, the system
automatically determines which mold components will be cut by the ejector pin hole feature.
• Info - Enables you to display information regarding the ejector pin hole feature in the browseL

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The mold components that are specified are displayed in the Intersected Comps dialog box. To rem� a.-..
components displayed, you can select the component and either click Remove or right-click and se..�
�h and Remove.
=eature
, in the Counterbore - Each ejector pin clearance hole contains a counterbore. You must also specify the
counterbore diameter and depth.

>m two

an axis
:cify the

tum axis.
to easily Fig 4.106: Ejector Pin Holes Fi9 4. 101: Ejector Pin Holes in Core
reated in
The following task explains how to create a coaxial ejector pin clearance hole:

e severa 1. Open ejector-pin.mfg. Select EJECTOR_CORE.PRT and click View > Display Style > Transparent.
holes a: 2. Notice the four ejector pin pads on the reference model.

3. Click Insert > Ejector Pin Hole from the main menu.
=0110... ...:

hole w
tersecteo

1es wh·
• hero-'!
Jde.s a-

Oe O!>.
Fig 4.108: Mold component to create eje pin

ie sysrem 4. In the menu manager, click Coaxial > Done.

D
.... 5. Select the datum axis A_6.
tSer. 6. Select the top surface of the EJECTOR_CORE.PRT and click Okay from the menu manager.

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7. Select EJECTOR_CORE.PRT and specify a hole diameter of 0.6.

Fig 4.109: Mold assembly to create ejc pin holes

8. Click OK from the Intersected Comps dialog box.

9. Type 1 .2 as the counterbore diameter and press ENTER.
10. Type 1 as the counterbore depth and press ENTER.
11. Click OK from the Eje Pin Hole dialog box.

Fig 4.110: Ejector hole

Create an On Point ejector pin clearance hole.

12. Click Insert > Ejector Pin Hole.
13. In the menu manager, click On Point > Done.
14. Select datum point eje-pin and click Done.
15. Select the top surface of the ejector_core.prt and click Okay.

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Fig 4.111: Other point to create to eje hole

&. Select EJECTOR_CORE.PRT and specify a hole diameter of 0.6.

"7. Click OK from the Intersected Comps dialog box.
·s. Type 1 .2 as the counterbore diameter and Type 1 as the counterbore depth.
·9. Click OK from the Eje Pin Hole dialog box.

Fig 4.112: Ejector pin hole

Create a linear ejector pin clearance hole

20. Click Insert > Ejector Pin Hole.
21. In the menu manager, click linear > Done.
22. Select the top surface of the EJECTOR_CORE.PRT as the placement plane.
23. Select the front left EJECTOR_CORE.PRT surface and type 5.5 as the offset distance.

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31.
32.
33, I

34. •

35. (

36. l

Fig 4. 113: Mold assemble to create eje pin holes

24. Select the front right EJECTOR_CORE.PRT surface and type 8 as the offset distance.
25. Click Okay from the menu manager.
26. Select EJECTOR_CORE.PRT and specify a hole diameter of 0.6.

37. c
38. r,
39. S1
di
Fig 4.114: Selected eje hole for clearance 40. T\
27. Click OK from the Intersected Comps dialog box. 41. Cl
28. Type 1 .2 the counterbore diameter.
42. c
as

29. Type 1 as the counterbore depth.

30. Click OK from the fje Pin Hole dialog box.

Fig 4.115: Clearance hole created This co

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Create a Radial ejector pin clearance hole.

31. Click Insert > Ejector Pin Hole.
32. In the menu manager, click Radial > Done.
33. Select the top surface of the EJECTOR_CORE.PRT as the placement point.
34. Select the datum axis A_ 1 as the radial dimension origin.
35. Select datum plane MOLD_RIGHT as the reference plane for radial dimensioning.
36. Type 45 as the angle and press ENTER.

Fig 4.116: Mold assemble to create last clearanct hole

37. Click Radius > Done from the menu manager.

38. Type 3.75 as the radius value. Click Okay from the menu manager.
39. Select EJECTOR_CORE.PRT and specify a hole diameter of 0.6. Click OK from the Intersected Comps
dialog box.
40. Type 1 .2 as the counterbore diameter and type 1 as the counterbore depth.
41. Click OK from the Eje Pin Hole dialog box.

42. Click Plane Display IDal, Axis Display /� and Point Display :� to disable their display.

Fig 4.117: Four Clearance eje hole created

This completes the task.

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Creating UDFs

User-defined features (UDFs) are groups of features, references and dimensions that can be saved for use
on future models. UDFs save time by helping you establish a library of commonly used geometry.

Fig 4.118: "Template• Model Fig 4.119: Highlighted Surface while defining Prompts

The following task explains how to create a UDF from a feature in a part model.
1. Open create_udf.prt. Right-click Extrude 2 in the Model Tree and select Info > Reference Viewer.
2. I n the Reference Viewer dialog box, notice that Extrude 2 references datum plane RIGHT and Extrude
1.

3. Click the down arrow next to Extrude 1 and cursor over each of the surface references.
4. Notice that the top, flat surface and the circular surface are the two references on the model.
5. Click Close from the Reference Viewer.

RIGHT
� RIGHT

Extrude 2 in CRI
E_UOF.PR!_

1 Extrude 1
--2--.,si'®---
Fig 4.120: Reference viewer

6. Click Tools > UDF Library from the main menu.

7. Click Create from the menu manager.

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8. Type keyway as the name in the message window and press ENTER.
9. In the menu manager, click Subordinate > Done > Add > Select.
10. Select Extrude 2 as the feature to add and click Done/Return.

Fig 4.121: Feature selected for UDF

11. Notice the top surface highlighted in green. This is the first required reference.
12. Notice that the message window prompts you to enter the prompt for the surface. Type sketching
plane and press ENTER.

Rg 4.122: First reference

13. Notice datum plane RIGHT highlighted in green. This is the second required reference.
14. Notice that the message window prompts you to enter the prompt for the surface. Type orientation
reference plane and press ENTER.

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Fig 4.123: Second reference plane

15. Notice the cylindrical surface highlighted in green. This is the third required reference.
16. Notice that the message window prompts you to enter the prompt for the surface.
17. Type cylinder surface and press ENTER.
18. Click Done/Return from the menu manager.

Fig 4.124: Reference surface

19. In the UOFdialog box, select Var Dims and click Define. T
20. Zoom in, on Extrude 2 and select the 2 dimensions. F
21. Click Done/Return > Done/Return from the menu manager. 11
22. Notice that the first dimension is highlighted. h
23. Notice that the message window prompts you to enter the prompt for the dimension. c

24. Type key width and press ENTER. l

tf
b
ti

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Fig 4.125: Placement of UDF

25. Notice that the second dimension is also highlighted.

26. Notice that the message window prompts you to enter the prompt for the dimension.
27. Type key length and press ENTER.
28. Click OK from the UDF dialog box, to complete the UDF creation.

Fig 4.126: Created UDF

This completes the task.

Placing UDFs
If you recreate the same geometry regularly when creating your design models, it can be more efficient to
have the system create that geometry for you, using UDFs. Creating geometry by placing a preexisting UDF
can be much faster than creating it new each time.
Updating a Modified UDF
If you make the placed group of features independent of the UDF, then it results in all the UDF information
being copied to the target model as a group without any associative ties to the UDF. If the UDF is modified,
the copied group is not updated. However, if you establish a dependency to the original UDF, then changes

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to the fixed dimensions of the UDF cause a change to the group. You must manually update the group to
the UDF change by clicking Edit > UDF Operations > Update All from the main menu and then regenerate
the model.

7.

Fig 4.127: Viewing References on the Original UOF 8.

9.

Fig 4.128: Selecting References for UOF Placement Fig 4.129: The Placed UDF

The following task explains how to Place a UDF for a keyway in a model:
1. Open place_udf.prt. Click Insert > User-Defined Feature from the main menu.
2. Select KEYWAY.GPH and click Open. Accept the default of Advanced Reference Configuration and
10. <:
click OK.
s
3. Notice that a reference model has been created for this UDF and will be displayed in a subwindow.
11. J
s
4. Notice that the first required reference is highlighted in green, in the subwindow.
5. Notice that Reference 1 is highlighted in the dialog box and the description prompt reads, sketching
plane.
6. Select a corresponding planar surface, as shown below.

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Fig 4.130: First Reference plane

7. Select Reference 2 from the dialog box. Notice that this reference is hig hlig hted in g reen, in the
subwindow.
8. Notice that the descri ption prompt reads, orientation reference plane.
9. Select a corresponding plane, as shown.

Fig 4.131 : Second Reference plane

10.
1mand
Select Reference 3 from the dialog box. Notice that this reference is highlighted in green, in the
subwindow.
dow.
1 1 . Also notice that the description prompt reads, cylinder surface. Select a corresponding surface, as
shown.
'.tching

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Fig 4.132: Reference surface

12. Click Accept :�I. The Preview dialog box appears displaying the default orientation.

Fig 4.133: UDF placed

13. Click Flip and then click Preview Feature � eto' �.

Fig 4.134: UDF placed in other direction

�
14. Click Complete Feature
This completes the task.

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Filling and Opening the Mold

After ext�acting �old c?mponent�, you can create the mold

result, known as the molding. You can create
the molding by simulating the filling of the mold cavity with
molten material through mold features such
as sprues, runners and gates.

You can then simulate the mold opening process in order to check the correctness ofyour design. Drah and
interference checks can be performed to verify proper mold opening.
Creating a Molding
You can create the molding by filling the mold cavity through the sprue, runners and gates.
Molding parts:
• Contain a Molding feature.
• Are fully-functional parts.
• Maintain a parent/child relationship with mold model components and features.
When a mold is filled, molten plastic is injected into the sprue and then it travels through the runners and
gates to fill the mold cavity. The solidified result is known as molding. There can be only one molding part
in the model at a time.
Pro/ENGINEER enables you to simulate the filling of the mold cavity and generate the molding. In addition
to the mold cavity, the sprues, runners and gates are also filled, to generate the final molding. The molding
part is created by using the following molding formula:
• Molding Sum of all current workpiece geometry - Assembly level cuts that intersect the workpiece
=

(waterlines, for example) - all extracted parts (sliders and cores, for example) - ejector pin clearance
holes
The molding part is created in the mold model and it contains a single Molding feature that contains the
solid geometry. The molding feature cannot be redefined, but the part is a fully functional part. You can
retrieve it in the Part mode and perform various operations on the molding part such as removing excess
material using Pro/NC, calculating mass properties and also generating a mesh for flow analysis. To save
the molding part, you must save the mold model before erasing it from memory or exiting from your
current Pro/ENGINEER session.
The molding part maintains a parent/child relationship with the mold components and assembly level
features. Therefore, the molding automatically updates, when changes are made to the mold components
or assembly level features. For example, if the sprue diameter is increased, the molding part automatically
updates, to reflect the larger diameter.

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Fig 4.135: Mold Model Fig 4.136: Component with runner and gate

The following task explains how to create a molding in a mold model:

1. Open molding.mfg. Select MLD_HUB_MOLD_CAVITY.PRT and click View > Display Style >

Transparent from the main menu.

2. Notice the sprue and runner.

Fig 4.137: Mold assembly

3. Click Molding > Create from the menu manager.

4. Type HUB_MOLDING as the Part name and press ENTER.
5. Press ENTER to accept the default Mold Part Common Name [hub_molding.prt].
6. Notice the new component created in the Model Tree called hub_molding.prt.

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Fig 4.138: Mold assembly with component

7. Right-click HUB_MOLDING.PRT and select Open.

>
8. Spin the model and inspect the molding part.
9. Notice the single Molding feature in the Model Tree.

Fig 4.139: Mold component

This completes the task.

Opening the Mold

You can simulate the mold opening process, to determine whether your final design matches your original
design intent. The mold opening process is a series of steps, containing one or more moves. You can specify
moves for any component or member of the mold model, except the reference model and the workpiece.
It is convenient to blank the reference model, workpiece and all mold volumes, as well as the parting lines
and surfaces before opening the mold.

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In order to simulate the mold opening process, you must define the following:
Define Move - An instruction to move one or more members of the mold model. When defining a move,
you must specify the following items:
• The members to be moved.
• The direction reference of the movement. You can select a linear edge, axis or a plane to indicate the
direction. When the direction reference is specified, an arrow indicates the positive direction.
• The offset value. The members move the amount specified in the direction of the reference specified.
The members move parallel to the edge or axis or normal to the plane. You can specify a positive offset
value or a negative offset value, to move the member in the opposite direction.
Define Step - A collection of defined moves for opening the mold.
You can also perform the following operations on the mold opening simulation:
Delete - Enables you to delete an existing step.
Delete All - Enables you to delete all existing steps.
Modify - Enables you to modify an existing step, by adding or deleting moves from the step.
Modify Dim - Enables you to modify the offset value of a given move. You must regenerate the mold
model in order, for the new value to take effect.
Reorder - Enables you to switch the order of existing steps. You can specify the step you want to reorder
and then select the step that you want it to become.
Explode - Enables you to simulate the mold opening by stepping through the sequence, in order, one step
at a time. Members included in the moves of the step are translated according to the specified offsets. You
can continue to step through all the steps in the sequence. A message in the message window indicates
when all the components in the mold model have been successfully exploded. Tl
Rules for Defining a Move
1.
You must remember the following rules when defining moves:
2.
• Each step may contain several moves that are performed simultaneously. 3.
• A member can be included in only one move, per step.
• A move may contain several members, but they all are offset in the same direction and by the sa,me
value.

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PULL DIRECTION
PULL DIRECTION

L •

•
Fig 4. 1 40 : Fu l ly Opened Mold Fig 4. 1 41 : Closed Mold

•
I' r

Fig 4. 1 42 : Partia lly Opened Mold

The fo l l o w i n g task exp l a i n s how to create a m o l d o p e n i n g seq uence of ste ps:

1. O pe n open-mold.mfg. Click Mold Opening ;�1 from the Mo/d too l b a r.

2. C l i ck Define Step > Defi ne Move from the m e n u m a na g e r.

3. Sel ect OPEN- M O LD_SLI D E R 1 . PRT a n d c l i ck O K from the Select d i a l o g box.

PULL DI RECTION

Fig 4. 1 43 : Sl ider selected to open

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4. Select the top, front edge to define the direction.

5. Type - 1 50 and press ENTER.
6. Click Define Move from the menu manager.
7. Query-select OPEN-MOLD_SUDER2.PRT and dick OK from the Select dialog box.

13.
14.

Fig 4.144: Slider moving direction

8. Select the top, front edge to define the direction.

9. Type 1 50 and press ENTER. Click Done from the menu manager.

•
15. Cl
16. Sf
17. St
Fig 4.145: Sliders opened

10. Click Define Step > Define Move.

1 1 . Select OPEN-MOLD_CAVITY.PRT and dick OK from the Se/ectdialog box.
12. Select the right. vertical edge to define the direction.

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Fig 4.146: Core Cavity opening direction

13. Type 250 and press ENTER.

14. Click Done from the menu manager.

Fig 4.147: Opened Core and Cavity

1 5. Click Define Step > Define Move.

16. Select OPEN-MOLD_MOLDING.PRT and click OK from the Select dialog box.
17. Select the right, vertical edge to define the direction.

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Fig 4.148: Direction to open component from core

23.
1 8. Type 100 and press ENTER. 24.
19. Click Done from the menu manager. 25.
26.
27.

•
Fig 4.149: Opened Core and Cavity ejected component

Simulate the mold opening.

20. Click Explode > Open Next from the menu manager.
21. Click Open Next two more times to step through the mold opening sequence. This
22. The OPEN-MOLD_CAVITY.PRT needs to open before the sliders.

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Fig 4.150: Sliders opened

23. Click Reorder > Step 1 from the menu manager.

24. Click Step 2 as the new step for Step 1 to become.
25. Click Explode > Open Next.
26. Notice that the cavity now opens first.
27. Click Open Next two more times to step through the mold opening process.

Fig 4.1 51 : Core cavity opened

This completes the task.

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Draft Checking a Mold Opening Step

You can perform draft checking on mold components during the mold opening sequence. You can use draft
checking to determine whether the mold components have the correct surfaces drafted and suitable draft
angles in order to facilitate the mold opening process.
In order to perform a draft check, you must first specify on which step of the opening sequence you want
to perform the draft check. You must also specify the following items to perform a draft check during the
mold opening sequence:
Pull Dir - Specifies the pull direction to be used for the draft check. You can specify the pull direction
using either one of the following methods:
• Specify - Enables you to select a pull direction. You can filter the pull direction reference by plane,
coordinate system, curve, edge or axis and specify the proper reference. You can also flip the pull
direction to the opposite side of the reference.
• Move Num - Enables you to specify a pull direction reference by specifying a move number in the
step.
• Draft Angle - Enables you to specify the desired draft angle to check.
• One Side/Both Sides - Enables you to specify whether the draft check is performed on one or both
sides of the direction reference.
•
Full Color/Three Color - Enables you to specify whether the display is shown using the full color
spectrum or with three colors.
• Part or surface to check for drafting - Once you have specified the pull direction and draft angle,
you must specify a part to check for drafting or a surface to check for drafting.

Fig 4.152: Opened Mold

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Fig 4.153: Draft Check on a Slider Fig 4.154: Draft Check on the Molding

.ne, The following task explains how to perform draft checks on mold opening sequence steps.
JUll
1. Open draft-check.mfg. Click Mold Opening � from the Mo/dtoolbar.
the 2. Click Explode > Open Next from the menu manager.
3. Notice that the DRAFT-CHECK_CAVJTY.PRT opens in the first step and that it opens upward.
4. Click Open Next from the menu manager.
110th 5. Notice that the sliders open next in the second step, horizontal to the mold model pull direction.

'Olor

Fig 4.155: Mold totally opened

6. Click Open Next.

7. Notice that the DRAFT-CHECK_MOLDING.PRT is ejected in the third step and that it opens upward.

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Fig 4.156: Ejected component

1 6.
8. Click Modify > Step 2 > Draft Check > Both Sides > Three Color > Done from the menu manager. 17.
9. Click Move Num > Move 1 from the menu manager. 18.
10. Type 2 as the draft check angle and press ENTER. 19.
11. Select DRAFT-CHECK_SLIDER1 .PRT and notice the draft.

Fig 4.157: Draft check for Slider1

20.
12. Click Continue > Setup Oft Ck from the menu manager. 21.
13. Select the Pull Dir check box and click Both Sides > Three Color > Done > Move Num > Move 2
from the menu manager.
14. Select DRAFT-CHECK_SLIDER2.PRT and notice the draft.
15. Click Done/Return > Done/Return > Done from the menu manager.

This

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1 6. C l i ck Modify > Step 3 > Draft Check > One Side > Fu l l Color > Done.
ager. 1 7. C l i ck Move N u m > Move 1 .
1 8. Type 2 as the d raft check angle a n d press ENTER.
1 9. Sel ect DRAFT-CH ECK_MOLDING.PRT a n d notice the d raft.

Fig 4. 1 59 : Draft angle check in component

20. C l i ck Conti nue a n d sel ect DRAFT-CH ECK_CORE.PRT a n d n otice the d raft.
2 1 . C l i ck Done/Return > Done/Return > Done > Done/Return.
1ve 2

Fig 4.1 60: Core d raft check

This com p l etes the task.

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Interference Checking a Mold Opening Step

Pro/ENGINEER enables you to check moving parts for interference with a static part for each move you
define. After you have defined a move, you must select a static part to check for interference with the current
part that you have defined for the move. Areas that are interfering either have their curves highlighted, as
shown in the figure or if interference curves cannot be found, the resulting interference is highlighted by
a red point, as shown in the below figure. You can delete the move and try another method of opening the
mold opening, to prevent the interference of parts. You may have to redefine your mold components.

Fig 4.1 61: Interference Curves Fig 4.162: Interference Point

The following task explains how to perform interference checking on mold opening sequence steps.

1. Open interference.mfg. Click Mold Opening � from the Mold toolbar.

2. Click Explode > Open Next from the menu manager.
3. Notice the INTERFERENCE_CAVITY.PRT opens in the first step and that it opens upward.

Fig 4.163: Mold opened

4. Click Open Next from the menu manager.

5. Notice that the sliders open next in the second step, horizontal to the mold model pull direction.
6. Click Open Next.

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H .. L_IVIVLIJl l'\l\J,rn 1 1 :;, t:j t:\.: Ll:U l [ I U l t: u11ru ::i Lt:JJ i::H I U U l d l I L U fJ t: f l ::i U fJ VV d f U .

·e
I, as

F i g 4.1 64: M o l d opened with sl iders

8. Click Modify > Step 1 > I n te rfe re nce > Move 1 from the m e n u m a n a g e r.

9. Qu ery-sel ect I NTERFERENCE_MOLDING.PRT as the static p a rt.

1 0. N otice that the m essa ge wi ndow states that no interferen ce was detected between the cavity a n d
the m o l d i n g .

• c� fat: inti,rferen£e in moVing part

• No interference was detected.
Fig 4. 1 65 : Message window

1 1 . C l i ck Static Part from the m e n u m a n a g e r a n d sel ect I NTERFERENCE_SLIDER1 .PRT.

1 2. N otice that there i s n o i nterference between the s l i d e r a n d the cavity.
1 3. Click Done/Retu rn > Done from the m e n u m a n a g e r.

Fig 4. 1 66 : Slider selected to check interference

1 4. C l i ck Modify > Step 2 > Interference > Move 1 from the m e n u m a n a g er.

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1 5. Select INTERFERENCE_MOLDING.PRT as the static part.

16. Notice the highlighted interference curves between the molding and the slider.
17. Click Done/Return.

Th

v
Fig 4.167: Interference place highlighted
Ye
1 B. Click Interference > Move 2 from the menu manager. >

19. Select INTERFERENCE_MOLDING.PRT as the static part. •

20. Notice the highlighted interference curves between the molding and the second slider. •

21. Click Done/Return > Done.

•

•
Rg 4.168: Interference place highlighted

22. Click Modify > Step 3 > Interference > Move 1 from the menu manager. •

23. Select INTERFERENCE_CORE.PRT as the static part.

24. Notice the highlighted interference point between the molding and INTERFERENCE_CORE.PRT.
25. Click Done/Return > Done > Done/Return.
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Fig 4.169: Interference point highlighted

This completes the task.

Viewing Mold Information

You can view information about your mold model any time when you are in the Mold mode by clicking Info
> Mold. You can view the following types of information about the mold:

• BOM - Displays a bill of materials of all components found in the mold model.
• Components - Displays information on all the components in the mold model, including reference
models, workpiece, extracted components and the molding.
• Cavity layouts - Displays information on all cavity layouts. You can view the coordinate system
references used for placement of the cavity, the layout type, the number of cavities in respective
directions, the names and locations of each cavity and the overall workpiece size.
• Split Volumes - Displays all volumes created in the mold model as a result of split operations. You
can view the mold volume name, its display status in the mold model and its feature ID.
• Created Volumes - Displays information on all sketched mold volumes in the mold model. You can
view the mold volume name, its display status in the mold model and its feature ID.
• Parting Surf - Displays information on all parting surfaces created in the mold model. You can view
the parting surface name, its display status in the mold model and its feature ID.
• Split - Displays all the split operations performed in the mold model. You can view the parent and
child feature ID's of the split, the parting surface used and the resulting volumes created.
• last Volume - Displays the last created volume in the mold model. You can view the mold volume
name, how it was created, its display status in the mold model and its feature ID.
• Shrinkage - Displays any shrinkage applied to the reference model. If the mold model contains
more than one reference model, you must specify for which reference model you want shrinkage
information. You can view the coordinate system specified for the shrinkage, the shrinkage formula
used and the shrink factors used.
You can specify whether you want the output displayed in an Information window within Pro/ENGINEER
or whether you want it written to a file or both.

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1 INIOl™A I IDN WINDOW (mold_mold-info_inf. J)

ORMATION WINDOW (mold_mold-info.inf
All Edit View
SKE
_ T
_C-
HE
__D A
_ _
HD _
l:AT
__
H_
ER
- _
E
D _
ltD _
LD OL
U
_-- S-
Of£--lH
- A
················-----------·----..,..----
OLD UOLUHES CREATED BY SPLITTIHG
Hold Uoluiw : LIFTER_UOl.1 · · · · · · · · · · · ···--·----------=-··-·
CrHt•d By : Slc•tcb

Displiy Status : llaaltH Uolu.e CAUI TY_UOL

FHtur• IDs 1U1(87) 11163(•> ted By TEMP-MOLD_UOL5 t

lay Status Blanked

12316(131)
Hold Uoluiw SUDER_UOl1

Crut•d By Sketch
ure IDs
Displiy Status Blank•d

Futur1 IDs 1511(19) 1538(111)

Uolu.e : CORE_UOL

Fig 4.170: Viewing Created Volumes Information Fig 4.171: Viewing Split Volumes Information

The following task explains how to investigate the information for a mold model:
1. Open mold-info.mfg. Click I nfo > Mold from the main menu.
2. Inthe Mold Info dialog box, clear all Show Info About check boxes except for Shrinkage. Clear the File
check box, leaving the Screen check box selected. Click Apply and click Close from the Information
Window.

1 1�1-0RMA l l(m W t
MJt'W {niol� mold info ,,.,, 1 )

•- : lllt.D-IHFl_R(F
1 is � bf sull119

hrink coorcfiut• s11stt• : CU (CrHted in I

x Octor • 1.tlS•
Y hctor • 1. •t:S•
z factor • 1. "n

Fig 4.172: Viewing Shrinkage Information

3. In the Mold Info dialog box, clear the Shrinkage check box. Select the Cavity Layouts check box and
click Apply.
4. Click Close from the Information Window.

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lI l
,}N W t t.i:,)(l\'I {mold mJ ld info 1nl J)

ewity U,.•t 1
-1: ..... ...._IEF
llo*l Dritia: lllU_KF_CS\'$
LaJIOUt DritiR: CH
r,,.: Shtl•
Tetal CMitiff: 1

x ' z
113.IM st.IM St.H7
-113.HI -7.166 -76.198
Total 16 .ltt 57 .H6 115 . Ill

Fig 4.173: Viewing Cavity Information

5. In the Mold Info dialog box, clear the Cavity Layouts check box. Select the Created Volumes check
box. Click Apply.
6. Click Close from the Information Window.
filt ' INfOW.IA IION w1rmow (mold mold 1nlo ml J)
ti
on
SllETCHED AHD 5ATHEllEO MOLD UOLUMES IH A'

MDl.d Uolu• : LIFTER_UOL1

CrHUd IJ : Slcetcll
Disp:Uf sutus : ll•nlln
FHtun IDs : 11111 (17) 1'61(•)

Mold Uolu• : SLIDER_UIL1

CrHt•d BJ
Displ•J Stltus : Bhnk1d
FHture JDs : 1511(19) 1591(111)

Fig 4.174: Mold Volumes Information

7. In the Mold Info dialog box, clear the Created Volumes check box. Select the Parting Surf check box
and click Apply.
8. Click Close from the Information Window.

and •
1 INFORMAllON WINDOW (mold mold info. inf.4)

IHFORMAT I O H OF ALL PARTIHG SURFACES IH I

------------························--·····

Parting Surface PARTIHG_SURF

Display Status Blanked
Feature IDs : 1 1568(123)

Fig 4.175: Parting surface Information

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9. In the Mold Info dialog box, clear the Parting Surf check box. Select the Split Volumes check box
and click Apply.
10. Click Close from the Information Window.
' INfORMAllON \'llNOOW (mold molcl info 1nl 'i)

lllLD U8l.lllE$ CREATED IY SPLITTltC IH A

---------·-·-····-----·····-····----·

llllld
l Uolu• : C9VITY_UOL
cr.atH a, : TUF-tlllD_UOLS NS Spl
Display Status : llHked
FHture IDs : 123.(131 )

llllld Uol1_1• : CORE_UOL

Created B!I : TE..-tlllD_UOLS NS sp'
Displa11 Status : Blanked
Featur.e IDs : 12157(931)

Fig 4.176: Viewing Split Volumes Information

1 1 . In the Mold Info dialog box, clear the Split Volumes check box. Select the BOM check box and click
Apply.
12. Click Close from the Information Window.
13. Click Close from the Mold Info dialog box.

-filt -
llLL IF MTDIM.S F• .._. c:.eJn ISSEll
------------···--··--'!
4.
---· - - -..-·-·
5.
LHEL 1 -..-11FI ISSlll
l£l(L 2 ........._
., ,.,
LnEL 2 MU-I___ ,_,
LE9EL 2 Ufif¥ ,..,
Lfia. Z. tllll: Nil
LEl£L Z lllStill Nil
LEUEL 2 LIFIEl'I Pall
LEVlL 2 LIFlEllZ P
iil
L£U£J. 2 St.IH111 Nil
LmL 2 SUIEll2 Pall

Fig 4.177: BOM Information

This completes the task.

6.

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i>ox Lab Session 4. 1

Splitting the Shower Head Mold

Split the workpiece

1. Open shower_head_mold.mfg. Click Split Mold Volume @ from the Mold toolbar.
2. In the menu manager, click One Volume > All Wrkpcs > Done.
3. Select the plug volume from the graphics window and click OK from the Select dialog box.

cfck

Fig 4.178: Mold Volumes and Sliders

4. In the menu manager, select the Island 1 check box and click Done Sel.
5. Click OK from the Splitdialog box.

Rg 4.179: Mold Volumes .Sliders and component

6. In the Properties dialog box, click Shade. Type TEMP-MOLD_VOL 1 and press ENTER.

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Fig 4.180: Separated mold volume

7. Select SHOWER_HEAD_MOLD_WRK.PRT, right-click and select Blank.

Fig 4.181: Blanked mold volume

Split the remaining mold volumes.

8. t
Click Spli Mold Volume � from the Mo/dtoolbar.
9. In the menu manager, click One Volume > Mold Volume > Done.

10. In the Search Tool, select TEMP-MOLD_VOL1 as the volume to split and click Add Item liiJ and then
click Close.
1 1 . Press CTRL and query-select the SLIDER_LEFT_TAB and SLIDER_RIGHT_TAB mold volumes.
12. Click OK from the Select dialog box.

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Fig 4.182: Sliders Selected to split

13. In the menu manager, select the Island 1 check box and click Done Sel.
14. Click OK from the Split dialog box.

Fig 4.183: Mold Volumes, Sliders and component

15. In the Properties dialog box, click Shade. Type TEMP-MOLD_VOL2 and press ENTER.

a then

Fig 4.184: Mold volume without sliders

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16. Click Split Mold Volume @ from the Mold toolbar.

17. In the menu manager, click Two Volumes > Mold Volume > Done.
18. In the Search Tool, select TEMP-MOLD_VOL2 as the volume to split and click Add Item � and then
click Close.
19. Query-select the skirt parting surface and click OK from the Select dialog box.
20. Click OK from the Split dialog box.

Fig 4.185: Parting surface selected for splitting

21. In the Properties dialog box, click Shade. Type CORE_VOL and press ENTER.

PULL DIRECTION

Fig 4.186: Splited Core

22. In the Properties dialog box, click Shade. Spin the model to inspect it. In the Properties dialog box. type
CAVITY_VOL and press ENTER. Orient to the Standard Orientation.

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hen

Fig 4.187: Spllted Cavity

23. Click Blank/Unblank � from the Main toolbar.

24. In the Blank - Unblank dialog box, select the Blank tab. Select Parting Surface p as the Filter.

Select part_surf_ 1 and click Blank. Select Volume eaJ as the Filter. Select temp-mold_vol1 and
click Blank.
25. Select Component 0 as the Filter. Select shower_head_mold_ref and click Blank.
26. Click Close.

Fig 4.188: Total mold volume assembly

27. Click No hidden BJ and inspect the mold model.

:ype
28. Click Shading CJ .
29. Click Save 191 from the Main toolbar and click OK to save the model.

30. Click File > Erase > Current and then click Select All 00 and OK to erase the model from memory.
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Fig 4.189: Total mold volume in wireframe

Extracting Shower Head Mold Components

31. Open shower_head_mold.mfg. Click Create Cavity Inserts e from the Mold toolbar.
32. In the Create Mold Component dialog box, click Select All CiJ. Press CTRL and click TEMP-MOLD_
VOL1 to deselect it. Click Advanced to expand it.

1 Credle Mold ( om pon�nl

,
i<•
%,;_ •r
� �· l 3
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#J
�1r " [
,
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4
4
4
[\' 4
�CA\lllY_VOl OCA\lllY_VOL llano

.e$CORE_VOL QCORE_VOL llano

i!d!PlUG_VOL OPWG_VOL Nono 4
�SUDER_LEFT_rAS ElSUDEILLEFUAB Nono
.e:llSUDEl\.lllGHT_TAS E)SUOER_lllGHT_TAS Nono

Fig 4.190: Create Mold Component window

33. In the Advanced section of the Create Mold Component dialog box, select Mold Volume and under it,
select cavity_vol. Edit the Mold Component Name to cavity and press ENTER.
34. Select mold volume core_vol. Edit the Mold Component Name to core and press ENTER.
35. Select mold volume plug_vol. Edit the Mold Component Name to plug and press ENTER.

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:JSUOEA_LEFT_TAB N-

N-

Fig 4.191: Create mold component window Advanced window

36. ln the Advanced section of the Create Mold Component dialog box, click Select All 00. click Copy
From lr3I,
37. In the Choose Template dialog box, select the mold_design_WF4 folder. Double-click templates, and
then double-click mm_kg_sec_part.prt. Click OK.
38. Notice the five newly created mold components in the Model Tree.

• �CAVTIY.PRT
• �COflE.PRT
+ E;JP\.UG.�T
)_ • e:JSUOEP._LEFT_TA8.PRT
• £;7SUDERJUGHT_TA8.PRT
+ Insert Here

Fig 4.192: Extracted models Model Tre�

39. In the Model Tree, right-click CORE.PRT and select Open.

40. Notice the Extract feature in the Model Tree.
41. Spin the CORE.PRT and inspect it.
42. Notice the surfaces that are in blue.
43. Notice the surfaces that arein reference model color.

44. Click Close Window [EJ to return to the mold model.

it,

Fig 4.193: Splited Core

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45. I n the M o d e l Tree, rig ht-cl ick CAVITY.PRT a n d sel ect Open.
46. Aga i n , notice the Extract fea t u re i n t h e M o d e l Tree.

47. S p i n the CAVITY.PRT a n d i nspect it.

48. Aga i n , notice the su rfa ces that a re in b l ue.

49. Aga i n , notice the su rfa ces that a re in refe rence model co l o r.

50. C l i ck Close Window [El to return to the m o l d m o d e l .

5 1 . C l i ck Save � from the Main tool ba r a n d c l i c k OK to save t h e m o d e l .

52. C l i ck File > Erase > Current a n d then c l i c k Select A l l I =� a n d OK to e ra se the m o d e l from m e m o ry.

Fig 4.1 94: Spl ited Cavity

,

O pe n i n g the S h ower H ead M o l d Model

Create the mold ing

5 3 . C l i c k Molding > Create from the m e n u m a n a g e r.
54. Type Shower_Head_Molding as the n a m e a n d press ENTER.
55. Press ENTER to a ccept the M o l d Part Co m m o n N a me.
56. N otice that the m o l d i n g is created.

Fig 4. 1 9 5 : Mold volume component h i g h l i g hted

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Simulate the opening of the mold

57. Click Mold Opening � from the Mold toolbar to simulate the mold opening process.
58. Click Define Step > Define Move from the menu manager.
59. Select PLUG.PRT as the member for the first move.
60. Click OK in the Select dialog box.

y.

Fig 4.196: Moving Insert

61. Select the left, vertical edge to define the move direction.
62. Type 320 as the movement value and press ENTER.

Fig 4.197: Moving direction for insert

63. Click Define Move from the menu manager.

64. Select CAVITY.PRT as the member for the second move.
65. Click OK in the Select dialog box.

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71

Fig 4.198: Cavity part selected to move

66. Select the left. vertical edge to define the move direction.
67. Type 230 as the movement value and press ENTER.

72.
73.

Fig 4.199: Opening direction of cavity

68. Click Done from the menu manager.

74.
75.
76.

Fig 4.200: Opened mold volume

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72. Sel ect the front, horizontal edge to define the move d i rection.
73. Typ e 1 30 a s the move m e n t va l u e and p ress ENTER.

Fig 4.202 : Slider open i ng d i recti on

74. C l i c k Defi ne Move from the m e n u m a nage r.

75. Sel ect SLIDER_LEFT_TAB.PRT as t h e m e m be r for the secon d m ove.
76. C l i c k OK in the Select d ia log box.

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Fig 4.203: Second Slider opening

77. Select the front. horizontal edge to define the move direction.
78. Type - 1 30 as the movement value and press ENTER.

Fig 4.204: Slider opening direction

79. Click Done from the menu manager.

Fig 4.205: Sliders opened

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80. Click Define Step > Define Move.

81. Select SHOWER_HEAD_MOLDING.PRT as the member for the move.
82. Click OK in the Select dialog box

•
Fig 4.206: Mold component selected to explode

83. Select the front, right, vertical edge to define the move direction.
84. Type 100 as the movement value and press ENTER.

•
Fig 4.207: Opening direction of mold component

85. Click Done from the menu manager.

86. Spin the model and observe the mold opening sequence.

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Fig 4.208: Exploded all parts

Perform a draft check on the PLUG.PRT.

87. Orient to the Standard Orientation.
88. Click Modify > Step 1 from the menu manager.
89. Click Draft Check > Both Sides > Three Color > Done from the menu manager.
90. Click Move Num > Move 1 from the menu manager.
91. Type 2 as the draft check angle and press ENTER.
92. Select PLUG.PRT.
93. Notice that in the area of the plug where there is a proper negative draft (the cyan color), there is also
a positive draft (magenta).
94. Click Done/Return > Done/Return from the menu manager.

Fig 4.209: Draft check

Perform an interference check on the PLUG.PRT.

95. Click Interference > Move 1 from the menu manager.
96. Select SHOWER_HEAD_MOLDING.PRT as the static part.

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97. Spin the model and observe the location of the detected interference.
98. Notice that this detected interference is at the same location as the positive draft.
99. Click Done/Return > Done > Done/Return from the menu manager.

Fig 4.210: lnttrference check

Redefine the PLUG_VOL mold volume to change the PLUG.PRT mold component geometry
100. Orient to the Standard Orientation.
101. Press CTRL and select SHOWER_HEAD_MOLD_REF.PRT and SHOWER_HEAD_MOLD_WRK.PRT from
the Model Tree.
so
102. Right-click and select Unblank.

Fig 4.2 1 1 : Mold volume

103. Edit the definition of Revolve 1 .

104. Right-click and select Edit Internal Sketch.

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Fig 4.212: Sketch to redefine

105. Drag a window around the existing sketch and delete it.
I

106. Click Centerline i and sketch a centerline on the vertical reference.

107. Click Hidden line @ and zoom in, on the top of the sketch.

108. Click Use Edge (j and select the three edges.

109. Click Close from the Type dialog box.

11
Fig 4.213: Edited Sketch
11

110. Click Line '- and sketch the four remaining lines. 11

111. Click Done Section v 11

11 •

12

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Fig 4.214: Redefined sketch

112. Orient to the Standard Orientation.

113. Click Shading 3.

1 1 4. Click Complete Feature �

Fig 4.215: Redefined mold volume

"��
115. Click Regenerate Se to update the mold model.
1 1 6. Press CTRL and select SHOWER_HEAD_MOLD_REF.PRT and SHOWER_HEAD_MOLD_WRK.PRT from
the Model Tree.
117. Right-click and select Blank.
118. Right-click PLUG.PRT and select Open.
119. Spin the model and notice the difference in geometry.

1 20.Click Close Window [El to return to the mold model.

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Fig 4.216: Redefined mold volume

Rerun the interference check in the mold opening sequence

1 2 1 . Click Mold Opening � from the Mold toolbar.

122. Click Modify > Step 1 from the menu manager.
123. Click Interference > Move 1 from the menu manager.
124. Select shower_head_molding.prt as the static part.
125. Notice that there is no longer any interference detected.
1 26.Click Done/Return > Done > Done/Return from the menu manager.

PULL DIRECTION

Fig 4.217: Exploded mold volume

1 27.Click Save 19 from the Main toolbar and click OK to save the model.

128. Click File > Erase > Current and then click Select All 00 and OK to erase the model from memory.
This completes the exercise.

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5. Project
Scenario

After completion of Mold Design training, you will use the skills acquired in the Mold Design course to
create the Mold design for Camera Front Panel. Here you have minimal instructions, because all tasks in
this project are based on topics that you learned upto now. There will be no step by step procedure.
In this project, you will complete the Core and Cavity extraction for Camera Front Panel. Students are
requested to note all the steps used for designing the Mold. Finally a report should be made and will be
evaluated and signed by the instructor.

Fig S.1 : Mold model

Reference Model

The model file Camera.prt is saved in your ProMold Lab Session > Project folder. Be sure to save all the
project models in the working folder. The Project folder contains a sub-folder named Completed. Here
you will find a completed version of each model in the project. These completed models can be used as
reference if required.
The following are the step to be followed for mold design.
Task 1: Analyzing the model
Inspect the model and analyze it to verify that it is indeed ready to be molded in part.

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Fig 5.2: Analyzed model

Task 2: Create the mold model

Ones mold model is designed and analyzed, you have to assemble in Mold module. For this project specify
single cavity mold.

Fig 5.3: Mold model cavity layout

Task 3 : Creating workpiece

Create mold volumes, which will be later extracted as core, cavity and slider in the mold design process.

Fig 5.4: Mold model with workpiece

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Task 4: Parting surface

Create parting surfaces. This parting surface is used to split the workpiece into separate mold volumes later
in the mold design process.

Fig 5.5: Parting surface

Task 5: Create the mold components

Split the workpiece volume into one or more mold volumes based on the parting surfaces. The main mold
volumes are classified into core and cavity Once the desired mold volumes are created and split, you can
.

create the mold components including sliders, from the mold volumes.

Rg 5.6: Mold components

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Task 6: Runner
Create runner according to your cavity layout. The figure below shows an example of how runner can be
designed. However you can design the runners according to the need.

Fig 5.7: Runners in workpiece

Task 7 : Filling and Opening mold

You can create the molding component that represents the filled mold cavity. Create the molding
component automatically by determining the volume remaining in the workpiece after extracting the
mold components.

Fig 5.8: Filling and Opening the Mold

Once you complete the project, prepare a final report on the design process and submit to the instructor
ror eva(uatron.

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 Before you Commence the Program
• Course Brochure I Detailed Literature
• Course Objectives
• Career Counseling
• Software Demonstration

• Receipt for the fee paid with Service Tax

• Register yourself for certification at www.caddcentre.ws

• Training Schedule I Course Calendar

• CADD Centre's Printed Course Reference Guide

• CADD Centre's Workbooks for use in lab

• Doy-wise Course breakup information

• Theory I practical training from qualified faculty
• Certificate request forms at the end of every Module

r - - •

�-On Co�ple�ion of the Program

I

_ _
• CADD Centre's course completion certificate with folder

• Alumni registration through www.coddcentre.ws

• Free upload of your resume at www.skillease.co.in for

Placement Assistance

To know more, write to: [email protected]

#5, P. S. Sivosomy Solai, Mylapore,

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