Tutorial m Works

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MoldWorks 2009

Tutorial

September 2009

PROPRIETARY RIGHTS NOTICE: All rights reserved. No part of this materialmay be produced or transmitted in any form or by any means, electronic,mechanical, or otherwise, including photocopying and recording or inconnection with any information storage or retrieval system, without thepermission in writing from R&B.

The information in this document is subject change without notice and shouldnot be construed as a commitment by R&B .

R&B assumes no responsibility for any errors that may appear in thisdocument.

The software described in this document is furnished under license and maybe used or copied only in accordance with the terms of such a license.

Copyright 2000-2009 by R&B

All rights reserved

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32 Shaham Str.

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ISRAEL


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0 Table of Contents

Chapter 1 1 Introduction 1-1

Chapter 2 2 Getting Started 2-1

2.1 Initial Mold Assembly...................................................................... 2-2

2.2 Initial Mold Base ............................................................................. 2-5

2.2.1 Coordinate system of Mold Base Creation ........................................ 2-5

2.2.2 Add Cavity Insert ............................................................................... 2-6

2.2.3 Add Slides .......................................................................................... 2-8

2.2.4

Initial Mold Base Creation ...............................................................2-11

2.3 Creating Standard Components................................................... 2-19

2.3.1 Create Screws...................................................................................2-20

2.3.2 Create Core Pins (using the ejector menu).......................................2-28

2.3.3 Create Ejector Sleeves......................................................................2-31

2.3.4 Create a Trimmed Ejector Pin..........................................................2-38

2.4 Cooling System ............................................................................ 2-42

2.4.1 Create a cooling cycle using a 3D sketch.........................................2-42

2.5 Runners & Gates.......................................................................... 2-51

2.5.1 Insert Runner System ......................................................................2-51

2.5.2

Insert Gates ......................................................................................2-55

2.6 Collision Checking........................................................................ 2-58

2.7 Editing Tools................................................................................. 2-60

2.7.1 Modify Component Position .............................................................2-61

2.7.2 Modify Component Parameters ........................................................2-63

2.7.3 Modify Attributes ..............................................................................2-64

2.7.4 Delete Components...........................................................................2-65

2.7.5 Modifying Plate Assembly ................................................................2-66

2.7.6 Modify Heat Exchange......................................................................2-69

2.7.7 Recalculate Components...................................................................2-71

2.7.8

Edit Mold Size...................................................................................2-742.7.9 Add Plate ..........................................................................................2-76

2.8 Drawings....................................................................................... 2-79

2.9 Bill of Materials ............................................................................. 2-81

2.10 CNC Output .................................................................................. 2-84


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Chapter 3 3 Multi Inserts 3-1

3.1 Layout............................................................................................. 3-2

3.1.1 Create the Core Inserts assembly ...................................................... 3-2

3.1.2

Create the pocket-cutting tool............................................................ 3-63.1.3 The Mold Assembly............................................................................ 3-9

3.2 MoldWorks.................................................................................... 3-11

3.2.1 Set the Mold coordinate system. .......................................................3-11

3.2.2 Create New Mold and Add Insert .....................................................3-12

3.2.3 Add Component ................................................................................3-13

Chapter 4 4 Non Standard Mold Bases 4-1

4.1 Based on a Standard Mold Base ................................................... 4-2

4.1.1

Add Stripper Plate. ............................................................................ 4-44.1.2 Add Raiser Plates .............................................................................. 4-7

4.1.3 Add an Ejector Retainer Plate..........................................................4-10

4.1.4 Add an Ejector Plate.........................................................................4-11

4.1.5 Add an Insulation Plate. ...................................................................4-12

4.1.6 Recalculate the Mold ........................................................................4-13

4.2 Based on a SolidWorks assembly................................................ 4-14

4.2.1 Add Leader Pins. ..............................................................................4-17

4.2.2 Add Connecting Screws. ...................................................................4-19

4.2.3 Fix the connecting device to the plates. ............................................4-21

Chapter 5 5

User Components 5-1

5.1 Hot Runner ..................................................................................... 5-2

5.1.1 Description ........................................................................................ 5-2

5.1.2 The Manifold...................................................................................... 5-3

5.1.3 The mold base.................................................................................... 5-4

5.1.4 Add the hot runner nozzles................................................................. 5-5

5.1.5 Edit the hot runner nozzles ...............................................................5-14

5.2 Runner and Gate.......................................................................... 5-16

5.2.1 Creating the runners.........................................................................5-16

5.2.2

Creating the submarine gate.............................................................5-21

5.3 Cooling ......................................................................................... 5-26

5.3.1 Creating the Brass plug baffles component. .....................................5-26

5.3.2 Modify BB-Baffles parameters..........................................................5-30

5.3.3 Creating thread-less pressure plugs component...............................5-31

5.3.4 Creating Connector plugs component ..............................................5-34

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5.3.5 Creating Pressure plugs component.................................................5-37

Chapter 6 6 Lifters 6-1

6.1

Declaration of the core inserts........................................................ 6-26.2 Adding the Lifters ........................................................................... 6-4

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11 Introduction

The following Tutorial leads you step by step through the main functionality ofMoldWorks. We have included comments relating to the mold design processso that the environment and the needs of the mold designer will be clearer tothose who are not familiar with the injection mold design process.

Each time you run this scenario MoldWorks will save the molds into theassembly files (one per mold) under the Example Files folders along withSolidWorks parts representing the plates and components of the mold. Theplates are named Plate1.SLDPRT, Plate2.SLDPRT and the components (in

general) Leader Pin-Catalogue Number-Group ID.SLDPRT (unless youchange the component name through the MoldWorks > Options menu). Inorder not to corrupt the original files, we recommend that you first copy thefolders containing the original files under the Example Files folders to abackup folder.

The MoldWorks menus are available in assembly mode only.

A folder can contain only one mold, since the names of the standard plate andcomponent parts are in general fixed (albeit that you can change them beforecreation of the mold through the MoldWorks > Options menu).

SolidWorks Settings

1. We strongly recommend deactivating the Save auto recover info every xchanges check box from Backups in the Tools > Option menu under theSystem Options tab, and the Feature dimensions check box inAnnotat ions Display from Detailing under the Document Propertiestab.

2. Under the Views menu deactivate Planes,Origins and Points.

3. Also check theAlways display text at the same size parameter on the

Document Properties tab underAnnotat ion Display in the Tools >Options dialogue box.

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22 Getting Started

The files here can be found in the NewHandle folder under theMoldWorks\Example Files directory.



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2.1 Initial Mold AssemblyActivateSolidWorks and open the file: Mold.SLDASM under the

NewHandle folder.

You will notice that this is an assembly of two instances called CarHandle.CarHandle is an assembly containing the core and cavity inserts as well as theside cores for a part called CarHandle. This assembly was created throughSplitWorks; however, MoldWorks can handle any SolidWorks assemblies orparts no matter how they are created.

Here we have hidden one of the cavity instances in to show the core.

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Open the (hidden) part called CarHandle from one of the assemblyinstances. You will notice that it has the color coding created by theSplitWorks environment.

Close the part



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Open the CarHandle assembly.

Hide CoreInsert_1 and show CavitInsert_1 (if not visible).

Here you can see the cavity insert with the side cores.

Close (without saving) the CarHandle assembly.



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2.2 Initial Mold Base

2.2.1 Coordinate system of Mold Base Creation

MoldWorks enables the user to set up the Mold Coordinate system at any

point and with any orientation in the SolidWorks world coordinate system. Thedefault Mold Coordinate System is set to Top Plane.

SelectPlane1.

ActivateMoldWorks > Mold Base >

Coordinate System orClick in theMoldWorks pallet. The Mold CoordinateSystemPropertyManagerappears.

Change to top view.

Scroll parameterdx to 105 to center the mold.

Change to front view. see the position of theparting plane.

Notice that you can rotate the Mold CoordinateSystem as well as flip its axis. This allows you tocreate the mold around the part (inserts) whereverthey are positioned.

Click .



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2.2.2 Add Cavity Insert

The first step in creating a mold base in MoldWorks is the selection of the

cores, cavities and side cores to be included within the mold (can be doneafter the initial mold has been created as well). Performing this before theinitial mold creation allows MoldWorks to estimate the mold size according toa set of user modifiable rules.

Activate the MoldWorks > Add User Part

menu or relevant icon . The Insert In-Placedialogue is opened automatically.

SelectCarHandle from the FeatureManagerdesign tree.

All the assembly parts are selected in one action. Select the CarHandle part from the dialogue and

press delete. In this case for convenience we donot want the actual part to be included in themold environment.

Select CoreInsert_1-1 and choose Core from thedrop down list.

Select the CavityInsert_1-1 and choose Cavity from the drop down list.



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The side cores will remain part of the mold with no specific definition. Thereason we add the inserts before the mold is created, is to enable the moldestimation utility. Inserts can be added any time after the initial mold hasbeen created as well.

Select CavityInsert_1-1 again and Click theAt tr ibute icon .

Fill the part attribute data with the information in the picture above. TheQuantity here (2) is the number of cavity inserts in the mold assembly. This

data is written to the part property custom fields and will be reflected in theB.O.M. when using the appropriate template file (supplied with the MoldWorksinstallation under the Userfolder).

ClickOK to return to the Insert dialogue.

Click the Solid Pocket icon and select the hidden parts CoreTool_Tand CavityTool_T (previously prepared) from the Insert Pockets folder.

This is another short cut method to automatically create the pockets for theinserts during the initial mold creation sequence.

When adding the inserts after the initial mold creation you can create pockets

with mold tools (same as here) or with cut-extrude tools within the add userpart dialogue (which are blanked out at this stage). You can also add insertswithout creating a pocket, and use standard SolidWorks tools to cut therelevant plates if necessary.

Click finish.



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2.2.3 Add Slides

Now we define the slides. Again slides can be defined before the creation of

the initial mold, or afterwards. We define them before the mold so that theestimation will take them into account as well.

Activate the MoldWorks > Add Slides or relevant icon .

Click to open the Slide Library.

The slide library is user extendable. The default standard slide libraries (underthe installation MoldWorks\Slide folder) appear with locks on the left, to showthat they are the standard libraries. You can use the browse icon

( ) to add user slide library folders to the Slide Library. Check theUser Guide to see how to create your own user slide libraries. Once a newfolder is added the system will always display the new folders unless deleted(the locked folders cannot be deleted through this dialogue).

Click on the GibAssemblies under the PCS library.

Click .

Now a dialogue with a list of the slide configurations is displayed.



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Choose the last configuration as shown in the picture above.

Click .

Now the system requests a face to which the slide must be connected.

Select the face of the first pin as shown in the picture above.



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Click .

The Slide is read in and positioned on the face selected according to the globalcoordinate system. The slide positioning dialogue now appears.

This dialogue allows you to move the slide on the plane of definition or rotate it.

Click .

Finally the Cam Pin Length dialogue appears.

Before the initial mold has been created the only active parameter on thisdialogue is the Stroke parameter. The Ref Plane1 will be the top face ofPlate2 (cavity plate) as soon as the initial mold is created. Refer to the UserGuide for an explanation about the other parameters.

Change the Stroke parameter to 0.25 to allow the pin to move out by.25inch.

Click .

Click .

Now add the slides on the other four pins use the so all you have to defineis the face of the pin. The Stroke will be defaulted to the last inputted i.e. .25.



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2.2.4 Initial Mold Base Creation

A number of manufactures all over the world

are making standard mold parts for MoldMakers. A Mold Base is an initial assembly ofmold plates and components that the moldmaker can purchase from a commerciallyavailable catalogue thereby shorteningmanufacturing time. MoldWorks includes adatabase of the commonly used catalogueswith a selection of the most commonly usedmold components. New catalogues andadditional mold components are added from

time to time according to the user wish list.ActivateMoldWorks>Mold Base> New

Mold orclick relevant icon from theMoldWorks pallet.The New Mold dialoguebox appears.

NOTICE that the size of the mold isautomatically calculated to fit the inserts, whichhave been defined according to estimationparameters defined under the Estimationsection.

Click the select button from the Name:parameter to list the available catalogues.

Depending on the units of the current document the selection will show eitherthe metric (mm) catalogues or the inch ones. In this Tutorial the document isdefaulted to mm and so we choose the TRAINING catalogue.

Make sure that Typeis set to Standard. We are going to create a standardmold base.

The other option ofType is Plates Only orNon Standard mold.

The Non-Standard type allows you to create a non-standard mold (modifyingthe general dimensions) with all the components positioned according to thecorners of the general dimension.

You can also create custom mold bases (or dies, jigs and fixtures etc.) byusing the MoldWorks>Add Plate menu or relevant icon (under the Usertab), on any assembly of standard SolidWorks parts.



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Click on the Estimation tab.

NOTICE that the Catalogue tab stays displayedwhen the Estimation tab opens. In order tosimplify the interface we have caused the differenttabs to toggle between them, except for theCatalogue tab which remains open all the time.However, data which is useful from one tab iscopied to another if necessary i.e. in theEstimation tab we see the Dimensions:parameter again.

Set the following parameters:S1 = 35, S2 = 25, S3 = 60, T1 = 5, T2 = 5

Click on to see the meaning ofthe parameters.

Click on to store these parameters as the new defaults.



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Change to top view, to see how the inserts fit in the general size.

Change to right view to see that the mold fits intoPlate2 and Plate3.

Click on the Thickness tab.

Make sure that the thickness ofPlate 3 = 76.

Click on in order to get the graphichelp that will help you understand plate namestructure. (You can change the names through theMoldWorks > Utilities > Options menu)

Click on the Option tab.

This tab includes optional mold components, which maybe included in the initial Mold Base.

Select the LocatingRing, Spacers and EjectorGuide check boxes as well.



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Next we will check out the Injection machine. This is an optional step and canbe skipped. The Injection machine can also be previewed after the mold hasbeen created.

Click onthe Right view.

Click on the Injection Machine button in the Catalogue section of the NewMold dialogue.

Mark the Display Injection Machine.

Here we can see a view of an injection machine with the mold. MoldWorksindicates the Minimum and Maximum Mold Height as well as the Maximumstroke distance. If the mold doesnt fit into the machine then MoldWorks willindicate where the problem is. In this view the mold seems to fit into theinjection machine.

The Injection machine data is read in from an external Excel file, whichcontains some standard injection machine data and can be modified to suityour needs.



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Click on the Top view.

Here we can see there is a problem since the columns go through the plates.

SelectSize 2 from the Size: box.

The injection machine now fits into the mold.

Activate the Right view again just to be sure.

Click .

Initial Mold Base, initial components and component holes are created.

Inserts initially defined are added to the mold at the end of the process.



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MoldWorks is fully integrated in SolidWorks. Check that in the SolidWorksFeatureManager design tree the mold plates and component are standard

SolidWorks parts positioned in the mold assembly. For each group ofcomponents one component part is created positioned and displayed in thefirst position, the other components of the group are positioned as instances ofthe first and are in hidden mode. Component holes are created using theSolidWorks Hole function (whenever possible) in order to take advantage ofthe hole annotation. Holes are created with clearance dimensions followingthe method used by the mold maker to manufacture them. This issue will bediscussed in subsequent steps.

The cavity and the slide pockets have been created by the tools, which existwithin their definitions.

The plates of the mold base are mated to allow modifications to propagatethroughout the mold.

The four basic sketches for the base plates, the two raisers and the ejectorplates are created.



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MoldWorks suppresses the displayed geometry before creating the mold baseand returns it to its default status at the end of the process.

Activate left view.

NOTICE that the cam pins have been extended automatically to the top face ofPlate2.



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As soon as a mold is created MoldWorks adds a MoldWorksFeatureManagertab to the SolidWorks Feature Tree Manager in order toorganize the MoldWorks information.

Click on the MoldWorksFeatureManagertab.

Open the Display Configurationfolder.

Choose the different configurationsand RHM button to Show Only (orResolve Only).

Activate isometric view.

The display configurations have beencreated according to the plates, which

need to be displayed when adding the various components.

Notice that the Mobile Side icon is colored in to show that we have chosen theMobile Side display configuration to show.


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2.3 Creating Standard Components

This Chapter will demonstrate the typical method we use in MoldWorks to add

standard components.The component-positioning sketch can be created in a part document or in theassembly document. You can create it in advance or on the fly. Differentvariations of the component-positioning sketch will be demonstrated later on.


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2.3.1 Create Screws

Click the RHM button on andselect Show Only in the MoldWorksFeatureManager Tree.

ActivateMoldWorks > Add Component or

click the Add Component Icon .

TheAdd Component control dialogue box andthe Component Library dialogue box appeartogether.

Click the Screws tab. Select the Cap Screw.

Click .

The Start Face dialogue box appears. Here wedefine the face from which the components willbegin. Actually the positioning sketch for thecomponents can be defined anywhere;MoldWorks projects the positioning sketch ontothis face.

Select the bottom face ofPlate3 as thestarting face for the screws. Make sure thatthe name of the face is entered into theSelected face text box.

Click .


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The Position dialogue box appears.

Change to wire frame mode.

Change to normal view.

Open the sketch palette and create the following sketch. (Connect thecenters of the corner fillet on one side and dimension 10 from the distanceon the other side)

This sketch will be used to define the positioning of the fixing screws. It is notmandatory to define it as a rectangle. Points, circles and polygonal lines canbe used as well. The sketch can be on any plane in any part or in theassembly. The actual positions are calculated from the starting face.

Notice that since we use floating dialogues for this set of menus all theSolidWorks functions are available (specifically the sketch menu). The sketch

automatically appears in the Selected sketch area and the number of pointsof component positioning points is automatically displayed in the dialogue.

Make sure that the Duplicate to instances button is activated. This insuresthat components, which penetrate an insert, will be duplicated to all its



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instances. Deactivating this button will create the components ONLY for thespecific insert.

Click

The Screw parameter dialogue box appears.And the initial preview of the screws at the 4locations is shown.

Change to front view and Shaded withedges.

Click the See Parameters icon .

The component graphic help appears.


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The graphic help defines all the modifiable parameters. Some of theparameters are of geometrical type (screw diameter) and some of functionaltype (tapping depth). You may scroll a leading parameter (D1 in this case)defining the standard components from the catalogue.

If you key-in for the leading parameter data which exists in the catalogue it willalso be recognized and all the standard parameters will be retrieved. You mayselect a standard component by catalogue number from the Catalogue box.

You may also type in alphanumeric data possibly creating non-standardcomponents.

Close the graphic help by clicking again.

Scroll parameterD1 to 10. This means that we are selecting an M10standard screw from the catalogue. Watch how the screws previewchanges.

Scroll parameterS1 (Screw Length) to 30.

NOTICE that the moment that the screws penetrate the core insert we seetheir duplication in the preview.

Click (not a mandatory step you could click on theinstead)



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MoldWorks issues a warning message indicating that the actual screw hole isshorter then the screw and allows the option of:

Yes do the correction (i.e. adjust Offset to push the screw further into the

plate and the insert)."As Is" do it as defined.

Back to return to the step dialogue box.

ClickBack to return to the step dialogue box.

The system goes back to Add Component dialogue box.

Before creating the screws all the component steps i.e. ComponentSelection, Start Face, Position Selection and Parameter Selection areavailable for modification.

Click the See Parameters icon . The component graphic help appears.

Select one of the core inserts andclick on the Measured Length icon .S1 will automatically jump to 40 which is the correct length of the screwusing the screw Thread Depth = 1.5Screw Diameter(this law can befound in the Rules Options tab under the MoldWorks > Options menu.)



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Click the Oversize tab.

The parameters in this tab define the clearancedimensions for the screw holes. D1 = 1.0 meansthat the diameter of the hole for the screw will be1.0 mm larger then the nominal dimension of thescrew. D2 = 0.5 means that the diameter of thehole for the screw head will be 0.5 mm larger thenominal diameter of the screw head. There is alsoa K value which is accessed through the horizontalscroll. You can change the default clearance

dimension and click the button tosave the new values as defaults (for this particularscrew) in subsequent sessions.

Click in the Add Component dialogue box.

The system creates all the relevant holes encapsulating them in a SolidWorksFeatureManager tree folder, with defined clearance dimensions, in Plate3 andin the core insert in one step. The holes are created with the SolidWorks holewizard function.

NOTICE the oversize between the component and the hole.



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MoldWorks Unique User Interface

This type of dialogue display (2 levels of dialogue box) is the typical unique

user interface that is employed in MoldWorks. The top dialogue box isdisplayed throughout the creation process; we call it the control dialoguebox. This dialogue box contains the steps needed in order to define theparameters for the specific process (in this case adding the insert to the mold

base). It also contains the (Create), (Create and New) and(Cancel). Clicking one of these icons completes the process.

The second level dialogue box (step dialogue box) is used to input thedifferent data needed to accomplish the process. It always has the

(Continue) icon at the bottom of the dialogue. This icon

displays the next step.During the process all the step dialogue boxes are available through thecontrol dialogue box. This is useful to modify data at any stage beforecompletion of the whole process.

MoldWorks unique user interface thus allows you to modify data at any stageof the creation process without having to retrace steps already performed,while at the same time guiding you through the process.



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2.3.2 Create Core Pins (using the ejector menu)

Now we use the ejector menu to add core pins to create the tapping holes in

the core at the end of the bosses. This time well prepare the positioningsketch in Plate6 first.

Click the RHM button on and select Show Only in theMoldWorks FeatureManager Tree.

Right click on the Plate6 in the FeatureManager design tree and select Editpart. (We are going to prepare thepositioning sketch, you can also dothis on the fly as before or prepare it atthe assembly level)

Select the bottom face ofPlate6. Open a sketch.

Change to top view.

Create the points connecting thecenters of the three bosses ofCoreInserts. (it doesnt matter whichinstance)

Delete the Coincident constraints toavoid floating dimension errors in the

FeatureManager design treeafterwards, since we penetrate thesebosses with the core pins.

Close the sketch.

Exit edit ofPlate6.

Change to isometric view.

Click the RHM button on Mobile Side and select Show Only in theMoldWorks FeatureManager Tree.

ActivateMoldWorks>Add Components orclick theAdd Component

icon .

Select the Ejectortab.

In the ejector tab selectEjector.



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Click .

The Start face is selected automaticallybottom face ofPlate6 (since this is an ejector

menu), but we need bottom face ofPlate8since these are core pins and not ejectorsand don't move with the ejector plates.

Click icon on Add Component dialoguebox

The Start Face dialogue box appears.

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Select the bottom face ofPlate8.

Click .

The Position Dialogue box appears.

Select the sketch that was created (in Plate6).

Click .

Change to top view.

Zoom to the area of the three bosses.

In the Ejector parameter dialogue box open thecatalogue list in order to select the ejector bycatalogue number.

Select ejectorRT 6-100.

NOTICE that the ejector preview changes.

Open the graphic help just to see that youmay control the H7 depth. Ejector holes will becreated with a H7 tolerance while the other holeswill be created with clearance dimension controlledin the Over Size tab. Close the graphic help whendone.

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Change to front view, and make thecore insert transparent..

Zoom to the bosses.

Select a point on the inner boss

Make sure that Length Type is setto Length.

Click the extract data icon inthe parameter dialogue box.

Ejector length parameter L iscalculated and the ejector preview arefixed according to the new data.

NOTICE that the preview shows the

components for both instances of thecore.

Click on the attributes icon(The Molding Type, Dim1, Dim2 are calculatedonly after the component has been created - so will not appear here).

NOTICE that the Catalogue Number is automatically the next size.

Click x to close the dialogue.

Click in theAdd Component Steps dialogue box.

The system creates all the necessary holes, in all relevant plates and the CoreInsert_1 instances.



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2.3.3 Create Ejector Sleeves

Now we will create ejector sleeves to eject the plastic part at the bosses,

around the previously created core pins.



Click the RHM button on andselect Show Only in the MoldWorksFeatureManager Tree.

ActivateMoldWorks > Add Component or

click the Add Component icon .

TheAdd Component dialogue box and theComponent Library dialogue box appearsimultaneously.

Select the Ejectors tab.

In the ejector tab selectEjectorSleeve.

Click .

The Position Dialogue box appears. The Start

Face is selected automatically for ejectors,as the bottom face ofPlate6.

Select the previously created sketch in thePlate6 in the FeatureManager design treeor from the screen.

Make sure that the sketch appears in thePosition box.

Make sure that the Duplicate Enabledbutton is activated.

Click .The Ejector Sleeve Parameter Dialogue boxappears.


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Open the graphic help just to see that you may control the H7 depth.Ejector sleeve holes will be created with a H7

tolerance while the other holes will be createdwith clearance dimension controlled in the OverSize tab.

Close the graphic help when done.

Change to front view

Key-in parameterD1 to 10.

Makesure that the parameterB1 is 6.

Choose ORT for the Length Type. This optionis used to find the first point of penetrationthrough the insert. In this case the bottom ofthe bosses is flat so this is the penetrationpoint we need.



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Zoom to the bosses (in wire frame mode). To see the top position of theejector sleeves.

NOTICE that the next standard size appears in the Catalogue: parameter (onthe dialogue of the previous page) even though the length is given as the exactcalculation.

NOTICE that the ejectors sleeves are duplicated automatically to the othercore insert instance.



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Click the Oversize tab.

We would like to have different clearancedimension (for D1 parameter) in the differentplates that the Ejector sleeve goes through.

Select the existing value (1.00). Enter0.6in the edit window and Click the Insert

After Selected Item button .


Select the new inserted value (0.6). Enter0.5 in the edit window and Click the Insert

Af ter Selected Item button .

The first value is the oversize for the firstplate/insert (Plate 6 the ejector plate), thesecond value for the second plate/insert etc. Ifthere are more plates/inserts then oversizevalues, then the second last oversize value is


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used for the rest of the plates/inserts (the last value for the last plate/insert (inthis case the core insert). If there are fewer plates/inserts then oversize valuesthen the extra values are ignored.

Click the button if you want the current oversize list to becomethe default settings for the Ejector Sleeve with leading diameter10mm.

Click in theAdd Component Steps dialogue box. The system createsholes, in all relevant plates and the Core Insert. Sleeves are duplicatedautomatically to the core inserts instances.

At this stage you may have an error in the sketch due to the automaticCoincident constraint edit the sketch to delete these constraints.



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Here is a diagram showing how the different oversize values affect the holescreated. The first oversize value is applied to the hole in the first plate, and thelast oversize value to the hole in the last plate. The values in between areapplied to the plates in between successively.


H7


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2.3.4 Create a Trimmed Ejector Pin

ActivateMoldWorks > Add Component orclick theAdd Component icon

.

Select the Ejector.

In the Ejectortab select Ejector.

Click . The Position dialogue box appears.

Select the top face ofPlate3.

Open a sketch.

Define a point at X= 70, Y=0.

Click and the component parameter dialogue box isdisplayed.

Change to front view.

Key-in 10forD1.



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Change Length type to Trim.

NOTICE how the system detects the appropriate ejector length and selects astandard longer ejector. See the catalogue number and the maximum ejectorlength indicated by the L parameter.

Activate the Ejector Lock icon .

Select the second lock type as shown in the picture below.



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NOTICE that you can override the ejector lock default dimensions and savethem as the new defaults for the selected ejector.

Change to the top view and zoom to the ejector preview area.

Rotate the ejector lock 90 deg by changing the Rot: parameter.


NOTICE the automatic duplication of the ejector with the ejector lock.



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Click O.K.

Click .

NOTICE the automatic trim of the ejectors and the slots of the ejector locks atthe bottom of the ejector plate.

Select Show Onlyfrom the RHM button on Mobile Side in the MoldWorks

Display Configuration folder.

Change to the isometric view.

More components (i.e. support pillars etc.) could be added in a similar fashion.



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2.4 Cooling SystemThere are 2 ways of creating a cooling system in MoldWorks.

- Heat Exchange method which allows you to create a cooling system from

a series of2D and/or3D sketches.OR

- Using the standard component wizard to create cooling pipes.

We will show how to create a cooling cycle using the new Heat Exchangefunctionality.

2.4.1 Create a cooling cycle using a 3D sketch.

First we will create a 3D sketch using the standard SolidWorks tools. Makesure that theAutomatic relat ions in the System Options tab under theSketch Relations/Snaps section check box is marked,


Show Isometric view in Wireframe mode.

Select the right face of the Plate3.

Click on the 3D sketch icon.

Click on Line and select the right view.

Create a point as shown below (halfway between the plate and the inserttowards the left side of the insert - doesn't have to be exact).



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Select the front view (by clicking on the triad z axis) and draw the 3segments as shown below. (Again don't bother with exact dimensions,although the line should pass through the middle of the insert base, abouthalfway up, and then to just before the screw across the insert)

Select the top view (triad y axis) and draw the next 2 segments across theinsert and back to approximately the vertical point where the linepenetrated the insert from the plate.



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Finally select the front view (triad z axis) and finish the sketch as shownbelow.

Below is an isometric view of the sketch.



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Exit the Line menu.

You can adjust the lines graphically as shown below so that they are practicallyeven in the x-y plane.

We could now dimension and add relations to the sketch i.e. Fix the first andlast points to the plate face with the On Surface relation, make sure that thelines are symmetrical and the end points on the same vertical level etc. Thiscan also be done after creating the cycle.

Select the Heat Exchange folder under the MoldWorks FeatureManagertree. (without exiting the sketch)

Click on the RHM button and select the menu Insert Cycle

If the 3D sketch is still current it will be automatically selected in the Selectedsketch(s) parameter box of the Positions tab in the Heat Exchange



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PropertyManager. You can also select this menu from the MoldWorks >

Heat Exchange > Insert Cycle or relevant icon .

Depending on the sketch you have created you will now see something similar

to the picture below.

Notice: If at this stage the parts are in shaded mode the system automatically

makes the parts affected transparent.In this example we see that one of the pipes is in red meaning that it is incollision with a component.

Note that if the current view was shaded then MoldWorks will create atemporary transparency to allow you to see the preview of the pipes andcomponents.

If you have a collision at this stage, exit the menu edit the 3D sketch and adjustthe lines from the top view as shown in the picture below, making sure that thelines do not cross or come close to the screws or the core pins.

(The dimensions must be from the plate faces)



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You can activate the Insert Cycle menu while in the 3D Sketch which willclose the sketch and add it to the Heat Exchange Property Manager.

Click on Preview Cycle to show only one pipe. You can work with all thepipes showing and the current pipe is highlighted in green, or just with thecurrent pipe showing.

Now we are going to browse through the cycle pipe by pipe and adjust the pipeand component definitions. MoldWorks creates a plug for every pipe andmakes a decision based on distance as to which face to extend the pipe. If a

line segment crosses a part boundary then a o-ring is created.

Select the Cycle tab. As you can see the pipe is diameter10.00 mm andextension 10.00 mm as defined in the settings (for inch documents thesettings are .5 and .1 respectively). You can change these setting prior to



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entering the PropertyManagerby RHM button selection on the HeatExchange folder and clicking on the Settings menu.

Select the Connectoricon under the components dialogue; see that thecomponents preview changes.

SelectConnector Type 2 from the Type parameterbox, and key-in a value of43.00mm in the Faceoffset parameter box.

Click on the Right Arrow in the CyclePipe(s) dialogue to browse to the next pipe. Nextcomponent is a pipe with o-ring. Notice that thispipe is defined in the plate even though the originalsegment crossed into the insert as well.

Click on the Right Arrow again. The other o-ringappears.

Click on the Right Arrow again.

Select the Connectoricon under the componentsdialogue and leave the default choice.

Click on the Right Arrow again. The first pipe in theinsert is now displayed.

Notice: Instead of clicking on the arrows you can selecta segment.

Key-in the Diameterparameter as 8.00 mm. Wewill create the pipe cycle within the insert withdiameter 8mm.

Click on the Right Arrow again. Here we see thatthe middle button has changed to a warning sign.

This means that there is more then one possiblesolution for the pipe extension direction. Clicking on themiddle button will toggle the preview through thepossible solutions, in this case either side or both sides,

Toggle until the pipe extends to the near side of the



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plate.

Key-in the Diameterparameter as 8.00 mm.

Click on the Right arrow again. Here we see that the middle button has

changed to a warning sign again. In this case choose the both side option. Key-in the Diameterparameter as 8.00 mm, and Click on the Right Arrow

again. Again an ambiguous situation, choose the near end extension side.Don't forget to change the diameter to 8mm. (You can always click on theleft arrow to go back or on the Right Arrow to carry on until you reach thepipe again).

Key-in the Diameterparameter as 8.00 mm for the final pipe.

Select the Position tab and click on Preview Cycle. You should see thefollowing preview.

Click .

Notice that the same cycle with components is created in the instanced insertas well. We will show how to edit the cooling cycle created through this menuunder the Editing Tools chapter.



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You can also create the same cooling cycle with the standard add componentwizard using the cooling section, however, the new method that we haveshown above is recommended since it creates the hole wizard holes and alsothe components. The editing is far more comprehensive.

Open the Heat Exchange folder under the MoldWorks Feature Managertree to see the technological information regarding the cooling cycles. Thistree also serves as the bases for the modification of the cooling cycle at alllevels.



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2.5 Runners & Gates

2.5.1 Insert Runner System

First we create a 2d sketch to describe the runner system.


Show Bottom view and zoom to the middle showing both cavity inserts.

Select the face of one of the cavity inserts and create the sketch as shownbelow. (The points coincide with the middle of the front segment of thecavities).

This point coincides with the middle of this segment.



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Click the RHM button on the Runners & Gates folder under theMoldWorks FeatureManagertree and select the menu Insert RunnerSystem (without exiting the sketch).

If the sketch is still current it will be automatically selected in the Selectedsketch(s) parameter box of the Positions tab in the Runner System... Youcan also select this menu from the MoldWorks > Runners & Gates > InsertRunner System or relevant icon.

You will now see the sketch below.

Note that if the current view was shaded then MoldWorks will create atemporary transparency to allow you to see the preview of the runners.

Click on Preview system to show only one runner. You can work with all

the runners showing and the current runner is highlighted in green, or justwith the current runner showing.

Notice: You will not see anything change on the screen at this moment sincethe default of the Browse type (under the Parameters tab) is By path andthere is only one path, however, if you change this to By segment then youwill see only one runner.



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Now we are going to browse through the runner system and adjust the shapesand parameters of the runners. By default the round runner system is createdas shown above with default parameters as defined in the Settings menuunder the Runners & Gates folder.

Select the Parameters tab. As you can see the round runner is selectedalong with the Browse type: By path (default) and Diameter: 5mm , SinkExtension: 5mm (= Diameter by default), for internal corners only. EndConditions are round at both ends.

Select the Modified Trapezoidal shape as shown below.

We can see that the shape of the runner onthe screen has changed, and that it is orientedin the wrong direction (we want to create therunners on the cavity inserts).

Modify the Orientation angle: to 180degrees (the spin box automatically jumpsin increments of 90 degrees).

Now the runners are in the correct position.

We want to modify the size of the sub runnerson each end. In order to do this we have tochange the Browse type: to By segment (bydefault it is By path and all the segments inthis path are displayed).

SelectBy segment from the Browsetype: drop down box. Notice that thedisplay on the screen changes to showonly the current segment.

Click on the right or left arrows to browse through the runners till one of theend runners is selected.



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Modify the Depth to 3mm .

Notice that the Width is automatically modified and theAngle is constant. If aspecific Width is desired, then change the width and the angle will be modified.

Click on Preview system (under the Positions tab) to show all therunners. The current runner is displayed in green.

Select the segment of the other end runner and modify its depth to 3mm as well.

Click .

The runner system is created.

Actually we could have created only half the sketch since the cavities areinstances, however, it is more intuitive to create the whole sketch, and thesystem takes into account the fact that there is an instance and doesnt createthe cavity twice.



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Notice: the technological information under the MoldWorks Feature Tree.

We use the MoldWorks Feature Tree for modifications of the runners, whichwe shall do later on.

2.5.2 Insert GatesWe can insert gates in 2 ways either as part of the runner system, or onindependently on any face.

Here we will add gates to the previously created runners.

Click the RHM button on the Runners & Gates folder under theMoldWorks FeatureManagertree and select the menu Insert Gate(s)

Notice: this can also be done through the menu system, the relevant icon orfromAdd Gate which can be found in the RHM button menu on any runner.If the runner has a free point then that point will be pre selected in the gate

dialogue. Pick one of the end points of the runner system sketch (make sure that the

sketch is visible and that Sketches is active under the SolidWorks > Viewmenu.



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The system automatically chooses a submarine gate and finds the entry pointinto the cavity, displaying the relevant face. A triad is displayed which can beused to move the gate on the screen. The startdiameter of the gate is chosen so that the gate will

reach the cavity. If the diameter of the start gate isgreater then the diameter of the runner a messagewill be issued.

Scroll on the Vertical deviation: spin box in adirection which will rotate the gate into the cavity(30 degrees). Hint: check the direction of thegreen triad arrow and if it points downwards (i.e.into the cavity) then scroll up to get a positiveangle.

The system shows the following information:The Penetration diameter: (0 by default) is thecone diameter at penetration (not to be confusedwith the area of penetration). It does however givean indication of the Penetration area: (which is justan informative parameter). The Penetration height:is also informative information only.

The cone angle defaults to 20 degrees (the defaultcan be changed in the Settings menu)

The Horizontal length: is calculated from the

penetration distance.

There is also a Placement section which allows youto move the gate by exact increments instead ofusing the triad.

Key-in Penetration diameter: of.4.

Unmark the Through end parameter on thePosition section which will cause the cone topenetrate through half the radius (leaving acrescent). The Penetration area and height will

be the previous value.

Click .

Note that the gate is created on the instance as well.



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Important:

There are two scenarios for the gate to penetrate the cavity exist:

- The gate penetrates the surface for the default cone angle, and a base of runner diameter. Awarning is given. In this case either the runner should be enlarged or the coneangle decreased until a satisfactory penetration diameter is achieved.


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2.6 Collision CheckingWith this menu you can check collision or thin walls between components,pipes, inserts and plate faces.

Click the RHM button on the Core Plate and select Show Only in theMoldWorks FeatureManager Tree.

ActivateMoldWorks > Utilit ies > Collision orclick the Collision icon toaccess the Collision Detection dialogue box.

SelectPlate3 from the FeatureManager design tree or click on thegeometry.

Scroll Safety Distance to 6.

ClickGo.



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In this case the collision is also detected between cooling pipes. MoldWorksdoes not distinguish between planned collisions of cooling pipes andmistakes.

The collision areas are shown in red and the components in collision areshown in blue.

The icon toggles between showing the areas in collision and thecomponents in collision.

Click the transparency icon to facilitate showing the collision areas.

ClickClose Part.



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2.7 Editing ToolsFour main sketches and a set of equations and mates define the initial moldplate assembly. Equations defining the relationship between the plates are

also created within each plate.The four sketches are:

Base Plate Sk define the base plates dimensions.

Raiser Plate4/5 Sk defines the raiser plates dimensions.

Ejector Plate Sk define the ejector plates dimensions

At any time after an initial mold has been created mold size can be modified.

Initial component positioning sketches are also created (depending on theoptions requested) including:

Leader Pins Centering

Ejector Guides

Injection

Return Pins

Spacers

Screw Static Side

Screw Mobile Side

Ejector Screws

Components are positioned using the Standard SolidWorks sketch function asshown in the chapter Creating Standard Components. Modification of thesesketches will modify the components. Component parameters and attributescan be modified and components may also be deleted.

The Cooling cycles and the Runnersystems have their own modificationtools which are activated through their folders within the MoldWorks FeatureManager tree.


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2.7.1 Modify Component Position

We will now add components to an existing group of components and modify

positions.

Select the MoldWorks FeatureManager Tree tab .

Click the RHM button on and select Show Only in theDisplay Configuration folder of the MoldWorks FeatureManager Tree.

Select one of the screws connecting CoreInsert1 to Plate3 either byselecting a screw hole from the screen or by picking a screw from theFeatureManager design tree.

In general the edit icons (menus) become active once a component (or plate)

is selected.

ActivateMoldWorks > Edit > Component Position orclick .

The positioning sketch is opened for editing.

Change to normal view.

Add a line connecting the mid points on the longer edges of the rectangle.



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Change the sketch dimensions as shown in the picture below. You mighthave to cancel an end point condition ofCoincident on the top right handside point.

Close the sketch. Two screws are added to the group. The positions of theother screws are updated.

NOTICE that we did not actually use a MoldWorks menu to accomplish this,only edited a SolidWorks sketch and closed it which triggered MoldWorks tomake the modifications. We could have selected this sketch through theFeatureManager tree or any standard SolidWorks identification mechanism.

In general changing the sketch will change the component position:

- Deleting points will delete the components

- Adding points will add components

- Moving points will move the components.



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2.7.2 Modify Component Parameters

Rotate Plate3 to see the bottom face.

Make sure that CoreInserts is displayed

otherwisethe Duplicate to instances will not work,and only one set of screws will be created.

Select one of the screws or screw holes fixingthe core inserts to the core plate. (Use the FaceFilter to select the screw hole face ifnecessary).

The MoldWorks > Edit menu and relevant iconsbecome active.

ActivateMoldWorks > Edit > Modify

Parameters or click onThe Component Parameter dialogue box appears.

Scroll D1 to 12. S1 stays at 40. In factMoldWorks looks for the closest length to theprevious one (equal or greater) and uses it asthe new length.

Click .

Notice the Force Rebuild icon next to the

button. If pressed then themodification will delete the holes and rebuild them(instead of a modification), useful when the holeposition gets corrupted (i.e. if a plate is added ormoved horizontally).



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2.7.3 Modify Attributes

Select one of the recently created screws from the FeatureManager design

tree i.e. Cap Screw-22

ActivateMoldWorks > Edit > Att ributes or click on

The attributes can now be modified.

Click on Cancel.

In the case of a plate or insert the Molding Type parameter (Core/Cavity etc.) isuseful when the core/cavity are created directly on the plates (2/3) and weneed the core attribute for the ejector trim and other functionality. The usermay also create permanent parameter fields in the MoldWorks > Utilit ies >Options dialogue under the General tab, or add to the parameter field for aspecific part under the File > Property dialogue under the Custom tab.



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2.7.4 Delete Components

Select the middle screw from the bottom ofPlate3.

ActivateMoldWorks > Edit > Delete orclick on .

The Delete Component dialogue box appears.

In this dialogue box you can delete either thecomponent that you selected or the entirecomponent group. The components and componentholes in each plate will be deleted.

Click on the Select Group button.

You can now choose which components not todelete by deleting them from the list box.

Notice: When rebuilding the deleted componentsmay reappear since we do not delete its positionfrom the positioning sketch.

Cancel out of this dialogue by clicking x.



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2.7.5 Modifying Plate Assembly

Select the MoldWorks FeatureManager Tree tab .

Click the RHM button on Mobile Side and select Show Only in theMoldWorks FeatureManager Tree.

Change to Isometric and shaded view.

Select Base Plate Skfrom the FeatureManager design tree.

RMB click on Edit Sketch.

Change to top view.

Click on the B dimension and scroll to 596.

Click .

See that the plate is now centered in the sketch, because of the equations.



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Click on SolidWorks OK icon .

All the plates are updated to reflect the new base plate dimensions. The

cooling cycle is not rebuilt and so a message concerning errors in Plate 3 willbe displayed. (We will correct this later).

NOTICE that the component positions have not been modified. You canmodify them in the same manner as the screws. These components which arecreated with the Initial Mold (i.e. default) have their own sketches. (Ignore theWarning error in Plate3)

Select Leader Pins Centering from the FeatureManager design tree.

RMB click on Edit Sketch. Change to top view.

Click on all the 220 parameter and scroll orkey-in270.

Click on SolidWorks OK icon ..

The leader pins and bushings are repositioned. The same can beaccomplished for the other components.



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NOTICE if there is no need to correct plate thickness this is the most efficientmethod to modify the mold.

NOTICE that SolidWorks now shows errors in Plate3 due to the fact that thecooling cycle has not been updated. One quick way to update the cooling cycleis to edit the sketch so that MoldWorks performs a new analysis of the cycleand corrects it.


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2.7.6 Modify Heat Exchange

RHM button on any of the pipe segments under the Cooling Cycle folder

and select the Edit Sketch menu.

MoldWorks opens the 3D sketch from which this segment originated.

Activate the top view (as shown above) and modify the end points.



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Close the sketch.

MoldWorks updates the cooling pipes and corrects the connector positions.The Edit Cycle menu is automatically activated to allow changes to the cycle ifnecessary; in this case no changes are needed.

Click to cancel.



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2.7.7 Recalculate Components

Now we are going to change the thickness of a plate. Change to the front view.

Double click onPlate9.

Again you can see the plate dimensions. These are NOT the Base Plate SKsketches from before. You CANNOT edit the length and width dimensionssince they are constrained to the Base Plate SK with equations.

Click on the height dimension 56 and scroll to 86.

Click .

Click on SolidWorks Rebuild icon .

The plates are moved according to their mates.

The mold plate assembly has been modified; however, some of thecomponents have to be corrected because a plate thickness has beenchanged. This will be achieved through the MoldWorks > Edit > Recalculatefunction or relevant icon.



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In the previous step we modified the mold plates, now we are going to checkthe components that have been affected and recalculate them.

SelectMoldWorks > Edit > Recalculate orclick on the relevant icon .Now we select the plates from which the effected components started (it is alsopossible to select the effected components directly)

Activate right view.

Select Plate6, Plate7 and Plate8.

Click OK.

The system previews and attempts to heal the affected components and allowsyou to scroll through the effected components and modify wherever necessary.

Activate right view.

Scroll using the right scroll icon components that have been healed arepreviewed in blue, and components which have NOT been healed are

displayed in red.We can heal components when the new length required due to changes in theplate thickness is in the range of the standard lengths for the specificcomponent diameter in use.

Scroll until we see the red preview of the Sleeve.



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Click on the Edit Component Parameters icon ( ).

This cannot be healed since the new length should be 210 mm (according tothe change we made in Plate 9), however, this component diameter does not

have a length of210 in the Training catalogue. In fact if we check under theCatalogue parameter we don't have a sleeve of the required length. We caneither create a non-standard sleeve of length 210 or leave the sleeve as it is.

Cancel out of this parameter block (i.e. leave the length as 180).

Scroll to the next item (the ejectors we use as core pins).

Click on the Edit Component Parameters icon ( ).

Here we can see that the length parameter has been adjusted and since thereis a standard length greater then the new length (for the leading parameter i.e.the diameterD1) the component has been healed.



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Here we can see that the ejector lengths have been adjusted and the newstandard RT 6-400 is displayed in the Catalogue parameter box.

Cancel out of this parameter block.

Scroll to the trimmed ejectors again they have been automatically healed.

Scroll to the ejector sleeves again they have been automatically healed.

We have finished scrolling through the components and fixing them.

Click on the Recalculate Component(s) dialogue to complete therecalculation.

2.7.8 Edit Mold SizeIn this section we will show how to modify the initial mold base including thecomponents.

Select the MoldWorks FeatureManager Tree tab.



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Click the RHM button on Mold and select Show Only in the MoldWorksFeatureManager Tree.

Change to right view.

ActivateMoldWorks > Edit > Mold Size or click on the icon.NOTE: The new mold size reflects changes that we made to the platedimensions i.e. the size is recognized as TRN 5060 and Plate9 is now 86.

Change to front view.

Select new mold Dimension as TRN 5080. Notice the difference betweenthe new and old mold sizes.

This process will adjust the initial mold (plates and components) to the newvalues then perform recalculation and healing on the extra components added.

Click to cancel.

NOTE: The Edit Mold Size will not be available if the mold has extra plates ora plate thickness has been modified to a non-standard value.



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2.7.9 Add Plate

To demonstrate how MoldWorks can recalculate the complete mold tool

discerning which plates and components have to be modified we use theAddPlate menu. Here we will create space for a hot runner system.

Click the RHM button on Mold and select Show Only in the DisplayConfiguration folder of the MoldWorks FeatureManager Tree.

Select the front view.

Activate the MoldWorks > Add Plate(s) menu or relevant icon .

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Select Plate2.

Change the Length: to 56.

Click .

Click on the right arrow in the Placementdialogue to move the new plate to the rightside.

Click to create without rebuild, since wewant to add more plates.

MoldWorks2009 Tutorial


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Click on the Plate Dimensions icon and select Plate2 again.

Change the Length: to 56.

Click .

Uncheck the Move Plates check box, so that Plate1 does not move.

Click on the left arrow in the Placement dialogue to move the new plate tothe right side.

Click to finish the process and recalculate.

The Recalculate dialogue box is automatically displayed.

Use the arrows to scroll through the components; in order to check which (ifany) should be modified.

Note: The connecting screws have been automatically healed. They are in thewrong position, so we will change their position afterwards



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Click to recalculate.

Now all the new components (i.e. the ones created after the initial mold) arerecalculated. This may take a few minutes. Notice the screw and bushing holes

are now corrected.



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2.8 DrawingsThe 2d drawings are created according to a user definable template or use thedefault templates supplied with the system.

Activate the MoldWorks > Util ities > 2D Drawings menu or relevant icon

.

In the first half of the dialogue, the user can

choose the template to use. The icon canbe used to designate the folder, whichcontains the templates.

The second half of the dialogue is used toselect the parts for which the drawings are

created. Again the icon allows you toselect the folder in which the drawings arecreated.

Click the icon and choose theMoldWorks\DrawingTemplates\mmTemplate folder.

SelectA1.

SelectPlate3 from the Design ManagerFeature Tree.

Check where the drawings will be created.

ClickOK.

The system will then create the drawings.This may take a few minutes; click Yes to thequestion about updating the assembly.



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OpenPlate3.SLDDRW and zoom into the top view.

Zoom into the right view and notice the cosmetic threads.



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2.9 Bill of MaterialsThe bill of materials is automatically placed in the properties of each partcreated.

Return to the Mold assembly.

OpenPlate3.sldprt from the FeatureManager design tree.

ActivateFile > Properties and click the Custom tab on the Summary Infobox.

You can use this information in the drafting module (or after creating a drawingwith the MoldWorks >Util ities > 2D Drawings menu)

Start a new Drawing.

ChooseA0 - Landscape.



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Check that Mold assembly is in the Part/Assembly to Insert parameter box.

Select the Next arrow.

Choose Single view,Isometric or ientation and use Custom scale 1:2.

Place the view on the right hand side towards the bottom of the drawing.

Click .

ActivateInsert > Tables > Excel Based Bil l of Material.

In the Select BOM Template box select the file MoldBom.sldbomtbt in theuserfolder under the path to the MoldWorks installation.

Click .

This file can be copied to the default SolidWorks BOM template folder to be

available by default.Here is an example of the BOM for this mold.



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Below is a magnification of a part of the BOM.



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2.10 CNC OutputThere are 2 separate output files which can be used for CNC or processmanagement.

Click on the menu MoldWorks > Utili ties > C.N.C or the icon .

The save file dialogue box appears and on validation the CNC text file iscreated, for each of the plates and inserts, including the positioning,diameters, direction, length, face data and technology of the holes. This is theinformation needed to create the G code.

Open the file (through windows explorer).

Here is an example of part of the CNC file outputted.

Click on the menu MoldWorks > Utilities > Operations Report or the

icon .

The save file dialogue box appears and on validation the Operation ReportXLS file is created. Following is a picture of part of the file.



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33 Mult i Inserts

In this section we will create a multi-insert mold in order to show the featuresof SolidWorks and MoldWorks, which we use to optimize the various steps.


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3.1 LayoutThe first step in creating a multi-insert mold is to create the layout. We do thisusing the standard tools from SolidWorks, which are well suited for this

purpose.3.1.1 Create the Core Inserts assembly

OpenCoreInsert from the Example File\MultiLayout folder.

This part contains 3 configurations. The Default configuration should be active.

Open a new assembly.



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ChooseCoreInsert from the Insert Component dialogue box which opens

and click . This will place it at the centre of the assembly.

Save the assembly as CoreInserts.

ActivateInsert > Component Pattern > Linear Pattern

SelectCoreInsert as the Components to Pattern.

Select the edge (might have to reverse the direction) in the z direction inthe following picture as the Direction1. Set D1 to 60 and the # to 4

Select the parallel edge (as shown in the picture below) in the +z directionas Direction2 and set D2 to 60 the # to 5. Make sure that the Pattern seedonly checkbox is marked.

Click .



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Select the instance on the left side and with RMB select Configurecomponent under the Component section.

Check the R_filets under the Configuration heading.

ClickO.K. to validate.

Perform the same for the insert on the right side (choosing L_filets as theconfiguration).



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3.1.2 Create the pocket-cutting tool.

Activate Insert > Component > New Part. Name it CorePocket_T. This

way MoldWorks will recognize it automatically as a tool in theAdd UserPart > Insert function.

Click on CoreInsert from the FeatureManager design tree and thenselect the bottom face as the reference plane.



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Select the arcs as shown below (using the Ctrl key). And click to copythem into the open sketch.

Connect the edges to form a close contour.



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ActivateExtrude Boss/Base function. Select the Up To Surface optionand select the marked face in the following picture.

Change to Edit Assembly mode and hideCorePocket_T.



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3.1.3 The Mold Assembly

Open a new assembly and select the CoreInserts assembly from the Insert

Component dialogue box.

Click to place it at the origin of the new mold assembly.

Save the file and name it MultiMold.

ActivateInsert >Reference Geometry > Plane. Select a face on the backofCoreInserts as the reference and set the offset to 10.

Click .

ActivateInsert > Mirror Components.

Select the offset plane from previous step as the Mirror Plane.

Select the CoreInserts sub assembly as the Components to be mirrored.

Make sure not to check the check box next to Coreinserts-1 since wewould like the mirrored assembly to be an instance of the selected one.

NOTICE if we create a left/right mirror then we will not be able to duplicate thecomponents since SolidWorks creates a NEW part and not an instance.



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Click ,

Click to create the mirrored sub assembly.



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3.2 MoldWorksNow we begin with MoldWorks.

3.2.1 Set the Mold coordinate system.

ActivateMoldWorks > Mold Base > Coordinate System .

Change to top view and wire frame mode.

Select the mold assembly top plane as the reference plane.

Click the Rotation button so that the coordinate orientation is as in the

picture above. We want the X direction of the mold to be parallel to the subassemblies length.

Change the origin of the Coordinate SystemDX=-40, DY=-30.

Click



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3.2.2 Create New Mold and Add Insert

ActivateMoldWorks > Add User Part

SelectCoreInserts. Set Insert type to Core.

Click on the Solid Pocket icon and notice that CorePocket_T has alreadybeen added to the Solid Pockets dialogue (due to the _T suffix).

Click .

ActivateMoldWorks > Mold Base > NewMold orclick relevant icon .

In this case the inserts will be added automatically to the mold and no need toadd them in a subsequent step. The mold catalogue size should be 2550.

Select the Catalogue tab.

Click .

Scroll to select as shown below.

Select Plates Only.

Click .



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3.2.3 Add Component

Select the Display Configuration tab .

Select from the Display Configuration tree and click ShowOnly.

ActivateMoldWorks > Add Component or relevant icon .

ClickScrews tab and selectCap Screw.

Select Bottom face ofPlate3.

Change to wire frame view.

Open a Sketch and define the following rectangle on the bottom left handinsert. Make sure that the duplicate button is pressed.



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Click .

The Screw parameter dialogue box appears.

Change to left view

Scroll parameterD1 to 6.

Scroll parameterS1 to 30.

NOTICE that as soon as the screws penetrate the insert they are duplicated.

Click . All the components are created in the plate and in the insert.



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44 Non Standard Mold Bases

In this section we will create 2 types of non-standard mold bases. The firsttype is based on a standard mold base to which we add or delete plates. Thesecond non-standard mold base is built from an assembly of randomSolidWorks parts.

Both mold bases when defined behave the same way as the standard moldbase with regards to component creation, component modification etc.


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4.1 Based on a Standard Mold Base

Open a new assembly by using the File > New menu and select the

Assembly template. Exit the Begin Assembly dialogue. Please use a mm document since the catalogue we are using in this tutorial is a mm one.

ActivateMoldWorks > Mold Base > New Mold or relevant icon .

The system will request to save the assembly. A mold can be created onlywithin an already saved assembly.

Save the new assembly.

When creating an initial mold through the MoldWorks > Mold Base > New

Mold or relevant icon MoldWorks first checks whether a mold already existswithin the folder, and warns the user. (If a mold already exists then clickContinue orQuit and change the folder in which the current assembly issaved).

Select the Non-Standard option from the Type: box.

Select the mold size TRN 5060 from the Dimensions: box.

Select the Mold Dimensions tab.

Click on button.

Here we see the graphic meaning of the general plate dimensions.



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Key-in the value 636 forB.

Key-in the value 300 forL.

Key-in the value 96 forM.

Here you can see how the components are automatically adjusted so that theystay at the same distance to the corners of the plates.

Click .



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4.1.1 Add Stripper Plate.

Change to isometric view and shading mode.

ActivateMoldWorks > Add Plate(s) or relevant

icon ; theAdd Plate control dialogue box isdisplayed.

This dialogue box allows you to create bothstandard plates for the mold using the Standardtab or select any SolidWorks part to be a plateunder the Usertab.

SelectPlate3 from the screen or theFeatureManager design tree.

Notice that all the plates from Plate3 down areautomatically moved.

Key-in the value 86 for the Height.

Click on the attribute icon.



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Type Stripper Plate for the Description.

Select 1.2311 from the Material drop down box.

ClickOK to exit.

Click .

The Placement dialogue box is displayed.

Notice the Move Plates box is checked by default.

We can add a plate to the top of the reference plate orto the bottom.

We shall see later that if the new plate is smaller thanthe reference plate, then we use the arrows to align italong one of the edges.

We can also position it in relation to the center of thereference plate using the DX and DY

Click in the control dialogue box to create thenew plate.

At this stage the new plate is created and the system

then checks which components have to berecalculated.

When it finishes, having found components torecalculate the Recalculate Component(s) dialoguebox appears, and the first group of components to berecalculated is previewed.



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Click on the arrows on the Recalculate Component(s) dialogue box to

preview the different component groups to recalculate .

Click on the Edit Component Parametericon to access the previewedcomponent parameters in order to modify them.

Click on .

We are going to add a number of plates at this time and we will perform therecalculate at the end of the process.

Note: Clicking on the Create Without Recalculate icon would havecreated the plate without entering the recalculate function thereby saving time.



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4.1.2 Add Raiser Plates

ActivateMoldWorks > Add Plate(s) or relevant icon

.

Automatically the Plate Dimension ( ) dialogue isdisplayed.

SelectPlate2 from the screen or the FeatureManagerdesign tree.

Change to the right view.

Key-in value 56 for the Width.

Key-in value 96 for the Height.

Click the attribute icon.

Key-in My10 for the Symbol.

Key-in Raiser Plate for the Description.

ClickOK.

Click .



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The Placement dialogue box is displayed.

In the Placement dialogue box click the front arrow.

The arrows indicate the side of the reference plate

along which the new plate will be positioned accordingto the top view. The center button is to center the newplate on the reference plate.

Click .

The plate is created and the main dialogue remainsopen.

Click to select new plate.

SelectPlate2-1 as the reference plate.

Key-in value 56 for the Width. Key-in value 96 for the Height.

Click the

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