MLD mt10420 v1803 W

UNIGRAPHICS
MOLDWIZARD DESIGN PROCESS

WORKBOOK September 2002 MT10420 - Unigraphics V18.0.3.2
EDS
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MoldWizard Design Process Workbook Publication History: Version 16.0.1.3 . . . . . . . . . . . . . . . . . . . . Version 16.0.2.2 . . . . . . . . . . . . . . . . . . . . Version 17.0 . . . . . . . . . . . . . . . . . . . . . . . Version 18.0 . . . . . . . . . . . . . . . . . . . . . . . Unigraphics NX . . . . . . . . . . . . . . . . . . . . June2000 August 2000 December 2000 October 2001 September 2002
Workbook / Project Introduction
Section 1
PURPOSE
This workbook provides an opportunity to apply the skills taught in classroom lectures and activities, without specific detailed instructions. This will help you to consolidate your skills by practice in a work like situation, and to identify areas where further assistance from your Instructor is needed.
Toy Wagon Assembly

You are the mold designer for an injection mold company. Your client has commissioned you to build a toy wagon.
The assembly part file for this project can be found along the following path:
...\ moldwizd \ wagon \
EEDS All Rights Reserved
MoldWizard Design Process Workbook
1-1
Rear portion of the Bed
Forward portion of the Bed Seat Foot Rest
wheel
Wheel
Axle Frame
The front and rear axles are standard steel parts. The following parts will need to be molded. These parts and their respective part files are listed below:
D D D D D
Axle Frame: Bed: Foot Rest: Seat: Wheel:
mdp_axfram mdp_bed mdp_ftrest mdp_seat mdp_wheel
1-2
MoldWizard V18.0.3 Unigraphics V18.0.3.2
Mold Project Initialization

Section 2
This section will address the following tasks for all five molded parts:
D D D D D
Project Initialization: Units, Project Path and Name. Setting the Mold Coordinate System. Assigning a Shrinkage Scale Factor. Defining the Workpiece. Defining the initial Mold Layout.
The following pages will provide the information needed to complete this multiple Mold Project Initialization process.
Axle Frame Seat
Bed
Wheel
Foot Rest
2-1
Axle Frame
Pivot Boss Inner Axle Clips Outer Axle Clips

2
Steering Hole
Part Name: Units: Project Path: Project Name: Mold Coordinate System: Shrinkage Scale Factor: Work Piece: Layout:
...\wagon\mdp_axfram User Discretion ...\wagon\axfram\ Default: mdp_axfram Origin: Midpoint of the edge shown. Orientation: As shown. User Discretion Default Dimensions Auto Center
TIP Use Set Project Project Path and Name to locate the project directory when ever the path differs from the location of the product model. Directories were created for you to keep each assembly separate from others; however, remember that you may also create exactly one new directory by typing a new directory name at the end of the project path.
2-2
Seat
Part Name: Units: Project Path: Project Name: Mold Coordinate System:
...\wagon\mdp_seat User Discretion ...\wagon\seat Default: mdp_seat The center of the outer bottom diameter of the part, as shown.
NOTE
Note: this will require moving the WCS and adopting it as the Mold Csys. The initial WCS, while close, is not in the correct position. User Discretion Default Dimensions Auto Center
Shrinkage Scale Factor: Work Piece: Layout:
2-3
Bed

2
Part Name: Units: Project Path: Project Name: Mold Coordinate System: ...\wagon\mdp_bed User Discretion ...\wagon\bed Default: mdp_bed Origin: The center of the diameter on the surface shown. Orientation: As shown. User Discretion Default Dimensions Auto Center Shrinkage Scale Factor: Work Piece: Layout:
2-4
MoldWizard Design Process Workbook EEDS All Rights Reserved
Wheel
Part Name: Units: Project Path: Project Name: Mold Coordinate System:
...\wagon\mdp_wheel User Discretion ...\wagon\wheel Default: mdp_wheel Origin: The center of the bottom diameter as shown. Orientation: As shown. User Discretion Set X_length and Y_length to 3in. or 75mm. A user defined round workpiece of the following dimensions may also be used: Diameter: 3in or 75mm Height: 2in or 50mm Auto Center
Shrinkage Scale Factor: Work Piece:

NOTE
Layout:
2-5
Foot Rest

2
Part Name: Units: Project Path: Project Name: Mold Coordinate System: Shrinkage Scale Factor: Work Piece: Layout:
2-6
ZC YC 1.0" in ZC XC
...\wagon\mdp_ftrest User Discretion ...\wagon\ftrest Default: mdp_ftrest Origin: Offset 1.0 inches from the center of the face as shown. Orientation: As shown. User Discretion Default Dimensions Auto Center
Patching the Seat Part

Section 3
In this section you will add Surface and Edge patches to the seat part.
The opening identified as and the two openings identified as will be formed using a slide mechanism. You will find that auto patch is not designed to cope with this particular intent, thus, you may add patches manually: . . Use Edge Patch as shown on the following page. . . Use Surface Patch as shown on the following page.
3-1
Step 1 Apply a Surface Patch across the two vertical slots on the inside face of the part.
Shade the part to verify that these two patches were created.

3
3-2
Step 2 Apply an Edge Patch around the closed edge loop shown below, to create a floor in the Foot Rest opening. There are eight edges in this closed loop.
floor
This completes Section 3: Patching the Seat Part.
Patching the Foot Rest

Section 4
In this section you will apply a Solid Patch to the Foot Rest part.
Two openings labelled must be patched. The contours lend themselves nicely to practicing your skills with Solid Patch.
4-1
Step 1 Use Create Box to generate a rough solid. Size the Box by selecting the THREE faces shown below: . . . One face as shown. . . . Two corresponding faces on either side of the part; only one is illustrated.

4
4-2
Step 2 Use Surface Split to refine the shape of the rough solid. Use the faces indicated below to refine the shape of the box using Surface Split.
Inside curved face Planar face (hidden) Planar face Outer blend face
Planar face shown Planar face with hole Planar face (other side) Outer blend face
4-3
Step 3 Use Solid Patch to unite the patch body (tool) to the part (target). Step 4 Edge Patch two vertical gaps. The solid patch leaves two small vertical gaps on either side of the solid patch. Use Edge Patch to close these gaps.
Tips on this Edge Patch Procedure:

D D D
Select the two edges shown below. Choose OK to Bridge Gap. Choose Close Loop.

4
4-4
Mold Layouts
Mold Layouts
Section 5
The following pages illustrate the mold layout for each of the five molded parts. Use the figures as a guide to set the csys and create a layout for each.
Axle Frame:
Balanced Two Cavity
Bed:
Linear Two Cavity
5-1
Mold Layouts
Seat:
Linear Two Cavity
Foot Rest:
Balanced Two Cavity

5
5-2
Mold Layouts
Wheel:
Balanced Eight Cavity, Rectangular or Circular
Step 1 Create 8 cavity layout.
5-3
Mold Layouts
(This Page Intentionally Left Blank)

5
5-4
Parting Definition and Cavity & Core Creation
Section 6
In this section you will complete Parting Line definition and the creation of a Cavity and Core for all five molded parts.
Axle Frame:
The Axle Frame has a simple parting. Use of Auto Process, Auto Patch, and accepting system defaults will provide satisfactory results.
6-1
Wheel:
The Wheel has a simple parting. Use of Auto Process, Auto Patch, and accepting system defaults will provide satisfactory results.

6
6-2
The Seat has a simple parting. Use of Auto Process and accepting system defaults will provide satisfactory results. Patching for slides in this part was carried out in Section 3 of this project.
6-3
Seat:
Bed:
The Bed parting lies on two different planes joined by a transition section .

6
6-4
Step 1 Define the Parting Line and Auto Patch the Axle Clips. Begin the parting operation per normal convention. Use of Auto Process, Auto Patch, and accepting system defaults will provide satisfactory results. Upon completing this step, the Parting Lines dialog should be open, with the parting loop displayed in the graphics screen.
Step 3 Create Parting Surfaces. In this step, create the upper and lower Bounded Plane parting surfaces first.
6-5
Step 2 Use the Edit Transition Curves function to identify the four curves that link the two parting planes.
Step 4 Sew the three parting surfaces.

6
6-6
Step 5 Extract the Cavity and Core Regions. Step 6 Create the Cavity and Core, accept all defaults.
Step 1 Locate crossover faces and subdivide them. Step 2 Search Parting Lines. Upon completing this step, the Parting Lines dialog should be open, with the parting loop displayed in the graphics screen. Step 3 Add four Transition Points:
6-7
Foot Rest:
Step 4 Create four Extruded Parting Surfaces.

6
6-8
Step 5 Sew The Surfaces.
Step 7 Create the Cavity and Core, accept all defaults.
Note that the Cavity Body is incomplete in that it does include the standing steel needed to fill the void seen in the Core Body.
6-9
Step 6 Extract the Cavity and Core Regions.
Step 8 Unite the Solid Patch Body (tool) that lies on layer 25 to the Cavity Body (target). Window to the Cavity part and use Unite in the Modeling Application to complete this step.

6-10
Seat Slide Head
Seat Slide Head

Section 7
In this section you will create the Slide head that is needed to form openings that receive the Foot Rest tongue and clips.
. . . The tongue of the Foot Rest slides into this opening. . . . The Foot Rest clips engage these two slots.
7-1
Seat Slide Head
Step 1 Create a solid body that will serve as the workpiece for the Slide Head.
-
Open mdp_seat_top, then select Window " More Parts and open mdp_seat_cavity. Create the profile shown below.
D
The profile can be created using Sketcher or explicit curves.
10
1.375" (35mm) . . . Height to match the top of the tongue opening .

-
Extrude the profile into the part a distance of 2.1 Inches or 53 millimeters.
7-2
Seat Slide Head
Step 2 Use Solid Split to refine the shape of the workpiece into a finished slide head.
Before Split
Target Body Tool Body
After Split
7-3
Seat Slide Head

7
7-4
Foot Rest Slide Head

Section 8
In this section you will create a Slide head needed to form the ribbed lower surface of the Foot Rest.
As the mold opens, slides in the core half need to move in the directions shown . Use the Profile Split function to form the needed Slide Head. Step 1 Window to the Core part and use Profile Split.
-
The Core Body will be the target. Chain along the profile shown on the following page . .
8-1
XC YC
ZC
Step 2 Complete the operation by extruding in the direction shown , accept the default extrusion length.
8-2
The Slide Head is illustrated in a partly open position.
8-3

8
8-4
eMold Base and Standard Parts

Section 9
This section will add Mold Base assemblies and Standard Parts to the cavity and core bodies of the five ongoing mold projects.
Axle Frame, Bed, Wheel and Foot Rest

Mold Base For these projects, use any Mold Base you prefer. Standard Parts Add standard parts and actions appropriate for each mold design.
Seat
Mold Base Inch Mold Design: DME Type B Index 10.875 X 12 AP_h = 4.875 BP_h = 3.375 DME Type 2A Index 2530 AP_h = 106 BP_h = 76
Metric Mold Design:
Standard Parts Add standard parts and actions appropriate for each mold design. The following page illustrates a dual cam pin slide that may be used.
9-1
Dual Cam Pin Slide

9
9-2
Design Challenge
Create slides in the axle clip areas of the bed and/or axle frame projects.
Final Details of the Tooling Assembly

Section 10
This final section may be used to add details of the mold design that include:
D D D D
Gates Runners Cooling Circuits Electrodes
Add these details as time permits. Two examples of Electrode designs for the Bed project are shown:
Bed Core Electrode
10-1

10
Bed Cavity Electrode

10
10-2

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UNIGRAPHICS

MOLDWIZARD DESIGN PROCESS

Proprietary & Restricted Rights Notices

Workbook / Project Introduction

Toy Wagon Assembly

...\ moldwizd \ wagon \

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Workbook / Project Introduction

Workbook / Project Introduction

Rear portion of the Bed

Forward portion of the Bed Seat Foot Rest

Axle Frame: Bed: Foot Rest: Seat: Wheel:

mdp_axfram mdp_bed mdp_ftrest mdp_seat mdp_wheel

MoldWizard Design Process Workbook

EEDS All Rights Reserved

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Mold Project Initialization

Mold Project Initialization

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Mold Project Initialization

Pivot Boss Inner Axle Clips Outer Axle Clips

MoldWizard Design Process Workbook

EEDS All Rights Reserved

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Mold Project Initialization

Shrinkage Scale Factor: Work Piece: Layout:

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Mold Project Initialization

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Mold Project Initialization

Shrinkage Scale Factor: Work Piece:

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Mold Project Initialization

EEDS All Rights Reserved

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Patching the Seat Part

Patching the Seat Part

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Patching the Seat Part

This completes Section 3: Patching the Seat Part.

MoldWizard Design Process Workbook

EEDS All Rights Reserved

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Patching the Foot Rest

Patching the Foot Rest

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Patching the Foot Rest

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Patching the Foot Rest

EEDS All Rights Reserved

MoldWizard Design Process Workbook

Patching the Foot Rest

Tips on this Edge Patch Procedure:

MoldWizard V18.0.3 Unigraphics V18.0.3.2

Balanced Two Cavity

Linear Two Cavity