IMOLD V8:
training guide
© Manusoft Technologies
Copyright © 2000-2007, Manusoft Technologies Pte Ltd
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1st Edition (IMOLD 2003) March 2003
2nd Edition (Service Pack 1) May 2003
3rd Edition (IMOLD2004) February 2004
4th Edition (IMOLD2004 Service Pack 2.1) September 2004
5th Edition (IMOLD 2005) January 2005
6th Edition (IMOLD 2006) March 2006
7th Edition (IMOLD V8) August 2007
IMOLD is a registered trademark of the Manusoft Technologies Pte Ltd.
Other brands and product names are trademarks or registered trademarks of their
respective holders.
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Table of Contents
Lesson 1 IMOLD Overview ............................................................................ 1 Lesson 2 Using IMOLD .................................................................................. 8
Overview ...................................................................................................... 9 Highlights ................................................................................................... 10
About the Part: ........................................................................................ 10 Process: Pre-Process Considerations ........................................................... 11 Process: Split Lines ................................................................................... 15 Process: Project Control ............................................................................ 18 IMOLD Assembly Structure: ....................................................................... 21
Lesson 3 Parting .........................................................................................24 Overview .................................................................................................... 25 Highlights ................................................................................................... 25 Draft Analysis. ............................................................................................ 25
Process: Draft Analysis. ............................................................................. 26 Parting ....................................................................................................... 26
Process: Parting Lines ............................................................................... 27 Process: Parting Surfaces .......................................................................... 29 Process: Sidecore Surfaces ........................................................................ 31 Process: Patching ..................................................................................... 34 Process: Runoff Surfaces ........................................................................... 36 Process: Create Inserts. ............................................................................ 38 Process: Copy Surfaces. ............................................................................ 39
Side Cores .................................................................................................. 43 Process: Create the side core. .................................................................... 43
Sub Inserts. ................................................................................................ 47 Process: Using Split Wizard ........................................................................ 49
Lesson 4 Layout and Feed System Design ...................................................51 Overview .................................................................................................... 52 Highlights ................................................................................................... 52
Process: Adding and Editing a Layout .......................................................... 52 Process: Adding Corners to the Inserts ........................................................ 54 Process: Add and Modify Gates ................................................................... 55 Process: Add and Modify Runner System ..................................................... 57
Lesson 5 Moldbase Design...........................................................................68 Overview .................................................................................................... 69 Highlights ................................................................................................... 69
Process: Loading a Moldbase ...................................................................... 70 Process: Purge ......................................................................................... 72
Lesson 6 Slider and Lifter Design ................................................................79 Overview: .................................................................................................. 80 Highlights: .................................................................................................. 80 Process: Slider Design.................................................................................. 80 Process: Create Slider Pockets – Automatic .................................................... 84 Process: Create Slider Pockets - Manual. ........................................................ 85
Process: Lifter Creation ............................................................................. 91 Lesson 7 Ejector System Design .................................................................96
Overview: .................................................................................................. 97 Highlights: .................................................................................................. 97
Process: Add Ejector Pins .......................................................................... 97 Process: Modify and Transform Ejectors ....................................................... 101 Process: Trim Ejectors ............................................................................... 102
Lesson 8 Cooling Design ............................................................................104 Overview: ................................................................................................ 105 Highlights: ................................................................................................ 105
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Process: Cooling Channel Creation ............................................................... 105 Lesson 9 Standard Components ................................................................118
Overview: ................................................................................................ 119 Highlights: ................................................................................................ 119 Process: Standard Components ................................................................... 119 Process: Main Insert Pocketing .................................................................... 132 Process: Adding Cooling Accessories ............................................................ 133
Lesson 10 Finishing the Design .................................................................136 Overview: ................................................................................................ 137 Highlights: ................................................................................................ 137 Process: Purge .......................................................................................... 137 Process: Create Configurations .................................................................... 138 Process: Create Pockets ............................................................................. 139 Process: Create Drawings ........................................................................... 139
1
Lesson 1 IMOLD Overview
Upon successful completion of this lesson, you should be able to:
Describe the features of IMOLD
Compare IMOLD and other mold design software
Describe IMOLD terms
Explain IMOLD modules
Lesson 1: IMOLD Overview
2
About The Course The goal of this course is to show how to use the IMOLD
software along with SolidWorks functions to complete a mold
design project. In the process we will discuss, in detail, the
functions of IMOLD. This training manual should be used as a
supplement to, rather than as a replacement for, other system
documentation and on-line help.
It is important for the students attending the class complete a
full mold design with the tools available while, at the same
time, learn the tools the software has to offer. The main focus
is to make our customers successful in the full design not only
concentrating on the functions of the software.
Prerequisites Students attending this course are expected to have the
following:
- Mold Design Experience
- Experience with the Windows™ operating system
- SolidWorks Essentials and Advanced SolidWorks Training
About this book It is our intention that this training manual be used in a
classroom environment being taught by an experienced IMOLD
instructor. It is not intended to be a self-paced tutorial.
This manual has been created following the same format as the
SolidWorks training manuals. It is our intention to make it
easier for the trainer to teach the IMOLD software by following
the same format as the SolidWorks training manuals.
The screen shots in this manual were made using IMOLD V8
SP0 running within SolidWorks 2008 on the Windows™ XP
Professional operating system.
IMOLD V8
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What Is The IMOLD
Software?
IMOLD (for SolidWorks) is a Windows-native 3D plastic injection
mold design application for SolidWorks. A very process-oriented
application and is developed by world-class R&D software
engineers, in conjunction with experienced mold design
engineers.
IMOLD provides mold designers with an indispensable range of
modules necessary for any type of mold design job. The full
integration within SolidWorks will enable the mold designers to
use a single integrated database throughout project
management, design, manufacturing, and mold assembly
management - the whole mold making process. Users do not
need to leave SolidWorks or make use of an external application
to accomplish their tasks.
IMOLD offers a range of functionalities in several modules that
are essential to the mold designer, and this will help an
experienced designer to shorten the overall lead-time needed
for a particular mold project, thus increasing productivity. The
user-friendly, user-interactive, and intuitive interface makes
learning how to use IMOLD very simple, thereby significantly
reducing the learning curve. As a complement to the
functionality it may also serve as an important learning tool for
the novice designer.
IMOLD Features IMOLD offers a vast array of tools that will aide in the
development of a mold design. The software offers tools in the
following areas:
- Data Preparation
- Project Control
- Core & Cavity Creation
- Layout Capabilities
- Gate & Runner Design
- Moldbase Library
- Ejector Design
- Slider Design
- Lifter Design
- Cooling Design
- IMOLD Drawings.
- Sub-insert Design.
Data Preparation Data Preparation is a module which assists the preparation of
product model. The following considerations apply:
- If the parting direction of the part is not along the z-axis
- If you do not want to work on the customer original part
This module will help you prepare the part so that should there
be any changes in the part eventually, these changes can be
reflected in the cores/cavities created in the downstream
process. In addition, tools like draft angle analysis and straddle
face checking are available.
You can also replace a model with another model of the same
part or a completely different part. This is very useful to handle
revisions and changes.
Lesson 1: IMOLD Overview
4
Project Control All IMOLD design projects starts here. Project Control is the
gateway from which design projects are started or continued. It
allows you to load current projects or start new ones. Here, you
may define the project code and unit, the resin type to use for
the project and the corresponding shrinkage factor. You can
also specify the various shrinkage factors here should you need
directional scaling. You may pre-define project options such as
which moldbase, slider, lifter and etc. vendor you wish to use in
the course of the project.
Core/Cavity Builder The Core/Cavity Builder provides the tools and utilities for
creating the core, cavity and sidecores. Parting the core and
cavity from the product model is achieved with the parting
surfaces identified automatically from the model and the run-
offs created.
The Core/Cavity Builder guides you, from defining the shape
and size of the main inserts, identifying the parting lines,
searching of the core and cavity surfaces, patching to splitting
the core and cavity.
The SplitWizard is a step-by-step wizard based part-splitting
tool. IMOLD SplitWizard assists as a first step to quickly and
easily split the product. Designers can automatically search for
inner and outer parting lines, automatic search for core and
cavity faces, automatically patching holes, automatically
creating run-offs and automatically create inserts. At the end of
each step, designers will receive more data regarding the part,
whether to continue with the next step or check what is wrong
with current process.
Layout Designer The Layout Designer provides the tools for laying out the
impressions in a multi-cavity mold. It also provides tools to edit
a layout and translate any of the impressions in the layout.
Feed Designer The Feed Designer provides the tools for designing the gating
and the runner systems. Gates like submarine gate and fan
gate are parametrically built so designers can easily design a
gate and add it into the layout. Linear and S-shaped runners
are offered for the various design needs.
The gates and runners can be automatically subtracted from the
inserts.
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Moldbase Designer The Moldbase Designer allows you to preview the moldbases
from various vendors before loading them in. You can also add
in double-ejection requirements with the click of a mouse
button and customize your plate thickness and location of the
components. Once you have finalized the design of the
moldbase, the Moldbase Designer will pocket out the
components from the plates and remove any unnecessary
parts. IMOLD has also set up the whole system such that you
can even create new moldbases that are unique to your
company.
Ejector Designer This module lets you add in standard ejector pins from various
vendors at locations of your choice. It also allows for customize
ejector pins through its interface. The Ejector Designer
automatically trims all the ejector pins to the core surface at
the click of a button and also a function to pocket out the
ejectors from the plates. Designer can add ejector pins together
with the sleeves effortlessly.
Components Gallery The Components Gallery provides a comprehensive range of
standard vendor components that you can add into your design.
The Components Gallery ensures that mating conditions are
adhered and the components are pocketed out.
Slider Designer The Slider Designer has incorporated standard slider bodies
and accessories within and allows the designer to add any of
these easily to the sidecore, or what we called sliderhead, so
that external undercuts can be manufactured in the injection
molding cycle. The software when designing the slider
automatically considers details like the positioning data, stroke
and cam pin angle with reference to the location of the slider.
The Slider Designer has both standard sliders and generic
slider in its database.
Lifter Designer The Lifter Designer works in a similar manner as the Slider
Designer except that it is used in cases where internal
undercuts are present. The module considers details like the
positioning data, stroke and releasing angle with reference to
position of the lifter.
Within its database of models, the Lifter Designer has options
for standard lifters and generic lifters.
Lesson 1: IMOLD Overview
6
Cooling Designer The Cooling Designer provides tools to design the cooling
circuits easily by specifying the cooling route. Once the circuit is
designed, it can be modified should any changes is necessary.
In addition, the Cooling Designer also makes considerations
for manufacturing by providing functions for drilling and
extensions.
The Cooling Designer also incorporates functions for adding
cooling accessories like nipples, o-rings and etc. automatically
to the cooling channels and to check interference between the
cooling channel and the other parts of the mold.
IMOLD Drawing IMOLD Drawing will automate the creation of the core and
cavity views of a mold.
Section lines can also be defined very easily by picking points
on the parent view.
IMOLD Drawings can also create drawings for all the parts of
the mold. It can also create hole tables.
IMOLD V8
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Process Flow IMOLD is set up in a manner to provide the user a sense of flow
while they are designing. The functions in the software are to
make the task of designing a mold much easier and faster thus
increasing productivity.
8
Lesson 2 Using IMOLD
Upon successful completion of this lesson, you should be able to:
Repair surface geometry
Change the part orientation
Create split lines
Begin a project
Identify the IMOLD assembly structure
Apply shrinkage
Continue a project
IMOLD V8
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Overview This chapter explores the considerations needed before you begin designing using
the IMOLD software and the tools available to satisfy these needs. In order for the
functions in IMOLD to work optimally, it is best to be working with solid body
geometry. We will discuss the tools available in SolidWorks to obtain solid geometry
from imported surface information.
The Z direction of the part file must match the parting direction. There are two ways
you can update your coordinate system to match this criteria. One is a technique in
SolidWorks for imported files and the other will be used for those native SolidWorks
files that you don’t want to lose information of the feature.
Here we will discuss the use of Project Control in order to begin and continue a
mold design project. The Project Control is where all IMOLD projects should begin
and continue. This module allows the user to choose the part that is to be molded,
add a resin type, add a prefix, etc. It will also allow the user to select the top most
level assembly to continue a design that has already been started. The designer must
determine the parting line and if certain surfaces need splitting you can use
SolidWorks Split Line command. Split Lines may also be used in locations where
it is difficult to obtain the proper parting surface. This will be discussed in more
detail during the lesson along with the rest of the topics.
In IMOLD V8 a new function Split Surface is available to effortlessly create of
split lines onto faces by selecting two points and a face. This decreases mouse travel
and events.
Lesson 2: Using IMOLD
10
Highlights Pre-Process Considerations – There are considerations that must be made before
you begin a project using IMOLD.
Split Lines – if certain surfaces need splitting you can use IMOLD’s splitting tool
from Data Preparation or alternatively use SolidWorks Split Line command.
Project Control – This is where all IMOLD projects begin and continue.
Assembly Structure – IMOLD automatically applies a pre-defined assembly
structure.
About the Part: The part used for the lesson is the cover for a switch component. In this model, you
will find multiple undercuts, which will require the use of both the slider and lifter
systems in order to mold the product.
IMOLD V8
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Process: Pre-Process Considerations
The SolidWorks Coordinate System
SolidWorks uses a system of coordinate systems with origins. A part document
contains an original origin. Whenever you select a plane or face and open a sketch,
an origin is created in alignment with the plane or face. An origin can be used as an
anchor for the sketch entities, and it helps orient perspective of the axes. A three-
dimensional reference triad orients you to the X, Y, and Z directions in part and
assembly documents.
IMOLD uses the Z-axis direction as the pull/parting direction. In cases where the pull
direction of the product was designed on a different plane, IMOLD provides an easy
to use tool to derive products from the customer part so that the associativity is
maintained to the original product and re-orienting the coordinate system is possible.
Imported Geometry
If the part is imported from a different CAD system, however, it may not always
come in as solid geometry. When there are only surfaces, there are tools available in
SolidWorks to help knit surface geometry into solid geometry.
Surface Geometry
Right Click on a surface feature in the Feature Manager Design Tree, select Import
Diagnosis, Diagnosis. This will help you to knit the surfaces into a solid. It is not
necessary to knit surfaces into a solid body, but it is recommended in order to take
full advantage of IMOLD functionality.
Lesson 2: Using IMOLD
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Data Preparation
Data Preparation will help you to reorient (rotate and move along different axis)
the product. The product should be oriented to the molding direction. A new product
is then created using the solid geometry from the original product.
Note: If you are using Data Preparation, you will not need to export the
part as Parasolid and re-import it into SolidWorks to change the origin or the
Z direction.
Introducing:
Data Preparation
Data Preparation is a tool that users may use to re-
orient their part by selecting the origin and the directions
of the axes.
Where To Find It: Click Data Preparation on the IMOLD Toolbar.
OR
From the IMOLD menu, select Data Preparation…
1. Data Preparation
Select the Data Preparation icon
from the IMOLD Toolbar and select
Data Preparation. Select the product
called and click
Open.
This part is an imported part and is
oriented in the wrong direction.
The Derive Property Manager is displayed. There are two options in
deriving the part:
i. Using draft analysis – steps 2 and 0. Refer to Lesson 3, Draft
Analysis.
ii. Manually – step 3.
IMOLD V8
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2. Draft Analysis
Click on the Draft analysis button. The draft analysis
tool examines the faces to ensure sufficient draft is applied accordingly
to the pull direction of the part. Additional functionalities includes:
identify and split straddle faces.
provides the designer with the
pull direction information.
automatically re-orient the part
to the pull direction accepted.
IMOLD uses the Front plane (Z-axis)
as the direction of pull. Under
Direction & Draft , select the
face as the plane for parting direction
and do a static analysis by selecting
the Static analysis option and click
Analyze.
From the results properties, toggle between the buttons , ,
and to show/hide the faces on the graphics area.
Straddle faces: faces that run between positive and negative draft.
There are 4 straddle faces identified from the analysis, but these
straddle faces do not interfere with the splitting of the core and cavity.
Should you need to split straddle faces, simply expand Split Surfaces
group box , click on Append Straddle
(automatically translates the 4 straddle faces into selection box) or
select the surfaces to split from the graphics area into selection box.
Click the Split button to split the selected straddles.
Click to accept the pull direction and bring back to the Data
Preparation PropertyManager.
Lesson 2: Using IMOLD
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3. Derive
On the Derive part dialog, you should be able to rotate, translate the
product accordingly. Check that the Z-axis direction is pointing
towards the pull direction. Click to derive the product.
4. Transforming the Product.
To manually transform the product, select the X-axis box under New
Coordinate System, select the edge shown below.
A triad is displayed with the 3
principal axes.
Click to select Flip direction if the
arrow (colored red) for the X axis is
not pointing in the direction shown.
TIP: Change the view to wireframe
mode to see the coordinate system
triad.
Select the Z-axis box.
From the FeatureTree, select the Right Plane.
If the Z-axis arrow is pointing downwards, click to select Flip
direction.
Click OK to derive the part.
Note: The Front plane of the top assembly will always be coincident to the
Front plane of the product model. In relation, the parting plane of the
moldbase is also coincident to the Front plane of the top assembly. Hence, if
you need to shift the parting plane of the moldbase, the original design has to
be done using a derived part. To change the origin of the part, you will have
use the Edit Derived Part function and reselect the origin and the axes of
the part.
In addition, please make sure that the origin of the derived part is contained
within the part. This is to ensure that the calculations for the containing box
are correct.
Refer to Lesson 3: Draft analysis for more details about the Draft analysis.
IMOLD V8
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Process: Split Lines When the user defines the parting lines, they must be edges of the project model,
and they cannot be curves or sketch lines. In some cases, SolidWorks Split Line
command must be used to split faces of the part so the parting lines can be defined
in consistence with good manufacturing practices and enable easy part extraction.
Split lines may also be required if the part does not allow you to easily produce your
parting surface.
Here we will also demonstrate the Split Surface function in IMOLD and how it help
reduce mouse travel and events.
Introducing:
Split Line
The Split Line function is used to divide a face into multiple
faces so that each face can be selected independently. Split
lines are used in mold design when a face crosses over the
parting line.
Where To Find It: Click Split Line on the Curves Toolbar.
OR
From the Insert menu, select Curve, Split Line…
Introducing:
Split Surface
The Split Line function is used to divide a face into multiple
faces so that each face can be selected independently. Split
lines are used in mold design when a face crosses over the
parting line.
Where To Find It: Click Split Line on the Curves Toolbar. Click Split
Surface on the CCB toolbar
OR
From the Insert menu, select Curve, Split Line…
Click Split Surface on the CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Utilities, Split Surface…
This sample product has a face that intersect the front plane. Let’s split this face to
keep the parting line simple. We will create the split line on the derived part so that
we don’t modify the original part.
5. Create a Sketch
Select the Right Plane of the
product.
Click to create a sketch.
Click to view normal to the newly
created sketch.
Select the edge shown.
Click Convert Entities .
Extend the ends of the line created so that it is longer than the face of
the tab.
Note: Be sure the line does not extend into the larger face, as this will cause
the split command to fail.
Lesson 2: Using IMOLD
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6. Create Split Line.
From the Insert menu choose Curve, Split
Line…
Under Type of Split selection box, select the
Projection option.
In the Selections box, choose the long side
face indicated by the figure.
Click OK .
The faces are split and an edge appears.
We will also add draft to the face for easier
extraction.
7. Create Split Line from Split Surface.
From the CCB toolbar select Split Surface
. Under Type of Split, select By two
points .
Select the surface indicated and under the
Entities selection box
, select the two
points used to split the surface and click OK
to split the surface.
IMOLD V8
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8. Add Draft.
Select Draft from the Features
toolbar.
Type Of Draft = Neutral Plane.
Draft Angle = 1.00deg.
Select the lower portion of the
parting surface as the Neutral
Plane.
Select the highlighted faces of the
tab as the Faces To Draft on both
sides of the part.
Click OK .
Draft is added to the part.
Save the product.
Select both faces
on both sides
Lesson 2: Using IMOLD
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Process: Project Control The Project Control is where all IMOLD projects begin and continue. In the
following steps we will be choosing the part to begin a project by defining the project
prefix, project unit, resin type, etc. These common parameters are essential for each
and every design using the IMOLD software. Upon the completion of the project
control module the assembly structure is created automatically, which in our case will
include an impression (core/cavity) assembly and top-level assembly. We will also
close and continue the project using Project Control.
We can also pre-define in the options tab such as the Project information, machine
type, insert information, the moldbase, slider, and lifter and component vendors
when initializing the project.
Introducing:
Project Control
To begin a project in IMOLD you must initialize the project
through Project Control. The Project Control module will
allow the user to browse and choose the part that will be
used for the design, provide the location of the working
directory folder, allow the user to choose a prefix, set a
project unit, and add a shrinkage factor.
In addition, you can import core/cavity inserts that you
have created in other CAD systems.
Where To Find It: Click Project Control on the IMOLD Toolbar
OR
From the IMOLD menu, choose Project Control
Introducing:
Starting A Project
Starting a project will create the necessary assembly
structure and files. This means there is no need to save
the files manually, it is all maintained automatically.
9. Project Control
On the IMOLD toolbar, select Project Control , New Project. The
Project Control
window dialog is
displayed.
10. Define Project Name
Enter Switch Cover as the project
name.
Add the plastic part
Click Add Parts.
Browse and locate the Switch
Cover_derived.SLDPRT file.
Click Open to load the part.
IMOLD automatically creates an assembly structure.
Note: You may have the part file open or closed when using Project Control.
IMOLD V8
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11. Provide a Prefix
Under Options, Enter 1000_ as the
Prefix.
Click to select Add prefix to all
standard components.
12. Select a Project Unit
Under Project Unit, select the Millimeter
option.
13. Select a Resin Type
From the project tree, select
1000_Switch Cover
derived_Impression.
Under Shrinkage, select the Apply to model option.
From the Resin drop-down list,
select ABS as the Resin.
This Resin Type will automatically
update the Shrinkage Factor to
1.005.
Introducing:
Working Directory
Prefix
Project Unit
Resin Types
Shrinkage Factor
The Working Directory is the folder location, which contains
all of the files for the mold design project.
The software offers the users the ability to add a Prefix to the
whole project. This parameter is for companies that use project
numbers to document jobs. It also allows the user to have
more than one project open concurrently.
The Project Unit controls the unit used throughout all of the
IMOLD modules.
The software offers a list of Resin Types, which will update the
Shrinkage Factor accordingly. The user also has the option to
manually specify the desired Shrinkage Factor or choose not to
add a shrinkage factor at all. When selecting the shrinkage
factor the user may choose to add a Uniform or XYZ scaling
factor.
Where To Find It: All of the above items can all be found in the Project Control
dialog Box.
Lesson 2: Using IMOLD
20
14. Start The Project
Click OK to start and create the project.
In addition, when creating the project you can set up the mold design specifications
like the moldbase vendor, component vendor and so on. The advantage here is that
users can preset the types of components that will be used for the project in order to
load them faster during the project.
Introducing:
Project Options
Project Options allows you to set options for the current
project. You can set options like:
- Customer Name
- Mold number
- Part finish
- Moldbase vendor and type to be used
- Slider vendor and type to be used
- Component vendor
- Lifter vendor
- And many more.
In addition, you can save these options to a database as
defaults for all projects (Company template) or for a particular
customer (customer template)
Where To Find It: All of the above items can all be found on the Options tab of
the Project Control dialog box.
IMOLD V8
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IMOLD Assembly Structure: The IMOLD assembly structure is created automatically when a project is initialized
through the project control module.
Top Level Assembly:
The top-level assembly contains all of the files created for the project mold design.
The system breaks the portions of the mold design into sub-assemblies making it
easy to work on different portions of the mold design at any given time.
Lesson 2: Using IMOLD
22
Introducing:
Clone Project
Clone Project will allow you to make an exact copy of the
project with all the associated drawings. The new project
can then be edited using Open Project..
Where To Find it? On the IMOLD Toolbar, select Project Control, Clone
Project
OR
On the SolidWorks Menu, select IMOLD, Project Control,
Clone Project.
Introducing:
Edit Project
Edit Project allows changes to be made to the structure of
an existing project. Some of the changes that can be made
are:
- Adding or removing parts.
- Changing the names of the inserts.
- Changing the shrinkage factor.
- Changing the project options.
Where To Find it? On the IMOLD Toolbar, select Project Control, Edit
Project
OR
On the SolidWorks Menu, select IMOLD, Project Control,
Edit Project.
Introducing:
Close Project
Close Project closes all the files associated with the
project. It can also save the files before closing them.
Where To Find it? On the IMOLD Toolbar, select Project Control, Close
Project
OR
On the SolidWorks Menu, select IMOLD, Project Control,
Close Project.
15. Close the project.
On the IMOLD menu, select Project Control, Close Project.
At the prompt, select Yes.
All the files of the current project are closed.
IMOLD V8
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Introducing:
Open Project
Open Project will allow you to continue work on an
existing project. This will load the assembly of the mold.
Where To Find it? On the IMOLD Toolbar, select Project Control, Open
Project
OR
On the SolidWorks Menu, select IMOLD, Project Control,
Open Project.
16. Continue the Project.
On the IMOLD toolbar, select Project Control, Open Project.
Browse and locate the file named: .
Click Open to open the project.
24
Lesson 3 Parting
Upon successful completion of this lesson, you should be able to:
Create core and cavity inserts.
Identify and create sidecores.
Familiarize yourself with the parting methods used in IMOLD.
Create sub-inserts.
Using SplitWizard to create core and cavity inserts.
IMOLD V8
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Overview We will be creating the main parts of the mold design in the following steps. To
accomplish this task we will be using the Core/Cavity Builder module in IMOLD.
Upon completion, we will have created a core, a cavity, a side core and a sub-insert.
We will discuss the different methods of parting as well as different techniques in
dealing with surfaces as they relate to each file. The Core/Cavity Builder provides
tools for creating the core and cavity of a mold, which can be created quickly and
efficiently with the interactive tools provided by the software. Any part, from simple
planar parting lines to complex free-form parting surfaces, can be created by the
Parting functions.
Highlights Create Inserts – IMOLD provides tools to easily create core and cavity insert
blocks.
Create Sidecore – IMOLD’s Sidecore function provides options to easily create side
cores.
Parting – IMOLD’s Parting Functions enable you to identify the core and cavity
surfaces of a part very easily.
Utility Functions – These functions make patching holes, creating run-offs and
copying surfaces across files much easier.
Sub insert Designer – This module helps the mold designer to easily design sub
inserts for inserts which require sub inserts.
SplitWizard – a step-by-step primary core and cavity, inserts splitting tool.
Draft Analysis. Draft plays a very important role in the manufacturing of parts by injection molding.
To ensure that a part can be successfully molded, it is essential that all the faces of
the part have draft along the pull direction. If any face lacks draft, the designer has
to decide if draft has to be added or if the part can be safely ejected as it is.
IMOLD provides tools to analyze the draft on a part, check for straddle faces and to
split them if necessary.
Introducing:
Draft Analysis
Draft Analysis checks for draft angle along the pull
direction (Normal to the Front plane) by default. In
addition, draft can also be analyzed along a pull direction
specified by the user. The tool can check for both faces
with zero draft and “straddle” faces – faces whose draft
angle is along both directions.
Where To Find It: Click Data Preparation , Draft Analysis… on the
IMOLD toolbar
OR
From the IMOLD menu, select Data Preparation, Draft
Analysis…
Lesson 3: Parting
26
Process: Draft Analysis.
1. Open the project.
Open using Project Control.
2. Draft Analysis.
On the IMOLD toolbar, select Data Preparation , Draft
Analysis…
Select the Front Plane for the Direction & Draft and click Analyze.
All the faces for core, cavity, zero draft
and straddle are tagged.
Select Keep Result option to maintain
the tagged result.
As this training guide will be demonstrating other methods of defining
the parting lines and surfaces, click Cancel to close the Property
Manager.
Note: In actual designs, add Draft angle to the faces highlighted using
SolidWorks tools. A discussion of adding draft is beyond the scope of this
Guide.
Parting Parting is the process of creating cores and cavities from a product model. In
general, parting consists of the following steps:
Identification of the parting lines, core and cavity faces of the part. During this
step, you also identify any faces that belong to side cores.
Patching – covering all the through holes on the part.
Creating runoff surfaces.
Creating the insert blocks.
Copying the core or cavity surfaces to the respective insert file along with the
patches and the runoff surfaces.
Splitting the insert with the surfaces.
IMOLD V8
27
Process: Parting Lines
Introducing:
Parting Lines
Parting Lines act as boundaries such that the search will
not go beyond these lines during the searching process.
Outer parting lines refer to the edges of the product,
round the position of maximum dimensions when viewed
in the draw direction. Outer parting lines will be used to
create run-offs as well as a guide to identify the
core/cavity surfaces.
Inner parting lines refer to the edges of through holes in
the product model which are shared by both the core and
the cavity. IMOLD will later use the inner parting lines to
automatically create patches.
Where To Find It: Click Core/Cavity Builder , Parting Lines… on the
IMOLD toolbar
OR
Click Parting Lines… , on the CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Parting Lines...
3. Identifying the Parting Lines
Click Parting Lines… , on the CCB toolbar. The Parting Lines
Property Manager will appear and under Operations click
.
Rotate the part to analyze the result of the auto search. In the
Parting Lines Property Manager, the outer parting lines and inner
parting lines are separated.
Lesson 3: Parting
28
4. Redefine the Parting Lines
The auto search function acts as a preliminary guide to defining
parting lines. Designers need to check the parting lines and
sometimes redefine them. In this case, we need to redefine the inner
parting lines.
Activate the Inner Parting Lines menu and on the design area,
deselect the unwanted edges and select the edges that make up the
new inner part loops that will become the inner parting lines.
Below is an example of how the inner parting lines should look like:
Click OK to accept the parting
lines.
IMOLD V8
29
Process: Parting Surfaces
Introducing:
Parting Surfaces
Parting Surfaces are the faces of the part that have
been identified as belonging to the core or the cavity.
They can be used to “part” the product model into the
core and the cavity.
IMOLD identifies the core and the cavity surfaces based on
the draft angles and the part topology. You can override
the automatic detection by selecting faces manually. You
can also set “limits” on the automatic detection by
defining parting lines.
Where To Find It: Click Core/Cavity Builder , Parting Surfaces on
the IMOLD toolbar
OR
Click Parting Surfaces on CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Parting Surfaces.
5. Identify the faces.
Click Parting Surfaces on the CCB toolbar
The Parting Surfaces PropertyManager is displayed.
Under Operations, click Search.
All the faces of the part are
identified and highlighted.
The actual colors may differ
based on settings.
The parting surface search did not utilize the parting lines define
earlier. To use the parting lines defined as a guide to search the
parting surfaces, select the Simple search option and click Search
again.
Lesson 3: Parting
30
6. Check the results.
Click the Explode View group to expand it.
A preview of the core and the cavity surfaces is displayed.
Under Explode View, click to unselect
Body option.
Notice that some faces that should belong to
the side core are tagged as cavity and the core
faces.
Click Reset under Operations to reject the
results.
Click Cancel to close the Parting Surfaces PropertyManager.
IMOLD V8
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Process: Sidecore Surfaces
Introducing:
Side Core Surfaces
Sidecore surfaces help to identify faces of the part that
will be formed by a side core.
Where To Find It: Click Core/Cavity Builder , Sidecore Surfaces on
the IMOLD toolbar
OR
Click Side Core Surfaces on CCB toolbar.
OR
From the IMOLD menu, select Core/Cavity Builder, Side
Core Surfaces.
Identify the side core faces.
Click Core/Cavity Builder OR
7. From the CCB toolbar, select Sidecore Surfaces
The Sidecore Surfaces PropertyManager is displayed.
Under Search Items, select the Boundary faces box to activate it.
Select the two faces shown.
Select the Seed face box to activate it.
Select the face shown.
Lesson 3: Parting
32
Click Search to search for the side core faces.
The faces belonging to the side core between the boundary faces are
highlighted.
Click OK to save the results and close the PropertyManager.
8. Re-identify the core and cavity faces.
Click Core/Cavity Builder ,
Parting Surfaces on the IMOLD
toolbar
The Parting Surfaces Property
Manager is displayed.
Under Operations, click Search.
All the surfaces of the part are
identified as core and as cavity faces.
The faces identified as the side core are
ignored.
Use the Exploded View to verify the
search result.
Since the parting lines are fully defined,
the core and cavity faces should be fully
assigned as well. In some cases, should
there be undefined faces still
unidentified, refer to the next step.
Click OK to close the Property
Manager.
IMOLD V8
33
We will use the IMOLD Core/Cavity Builder FeatureManager to move all the
unidentified faces to the core.
Introducing:
IMOLD Core/Cavity
Builder Feature
Manager
The IMOLD Core/Cavity Builder Feature Manager
shows all the faces in the faces in the part, grouped by
their identity. It also shows the patch and runoff surfaces
as well. With the Feature Manager, you can:
- Hide or show selected groups of faces.
- Select groups of faces.
- Move faces from one group to other.
Where To Find It: The IMOLD Core/Cavity Builder FeatureManager can be
found as one of the tabs in the PropertyManager
OR
Click Assign surface from the CCB toolbar.
9. Assigning faces
Activate the Core/Cavity Builder
FeatureManager by clicking the icon on the
SolidWorks PropertyManager.
Defined faces, parting lines and other
information is stored in the folders.
Right-clicking the folders will give you the
options to assign the faces.
When options are assigned, the
faces will move to the folders.
Lesson 3: Parting
34
Process: Patching Patching is the process of covering holes on the part so that a closed surface can be
obtained for splitting the core and the cavity.
Introducing:
Patch Holes.
Patch holes provides the tools required to patch holes. It
provided many different methods that can be used in
various situations.
Where To Find It: Click Core/Cavity Builder , Utilities, Patch Holes
on the IMOLD toolbar
OR
Click Patch Holes on the CCB toolbar.
OR
From the IMOLD menu, select Core/Cavity Builder,
Utilities, Patch Holes.
IMOLD provides 6 methods for patching holes. A brief description of each method and
where it is to be used follows:
Introducing:
AutoPatch: This covers all the holes in the part that lie on
one face and at the interface of the faces identified as core
and cavity.
Patch: This creates standard SolidWorks planar surface
and filled surfaces that are associative to the model. Use
this method when the model is a SolidWorks model and
you expect many changes in the model.
Delete hole: This creates a SolidWorks Delete Hole
feature. Use this method in the core and the cavity
surfaces to remove holes that span multiple complex
faces.
Untrim Surface: This removes all the holes from a face
and creates a new surface. The new surface is not
associative to the base surface. Use this method when the
face has many holes that would be too tedious to patch
one by one.
Circular Patch: This will create patches on a circular
edge. Use this method when you want to close the end of
a cylindrical surface.
Boundary Patch: This creates a patch on a selected
closed boundary.
Where To Find It: All the patching methods described above can be found
under Methods in the Patch Hole PropertyManager page.
IMOLD V8
35
10. Patch holes.
Click Core/Cavity Builder , Utilites, Patch Holes on the IMOLD
toolbar.
Under Methods, select the
Auto Patch option.
Click OK to create the
patches.
11. Alternatively, use FeatureManager to
create patches.
Select the Inner Parting Line folder and
right mouse click to show options.
Select Create Patch.
This function automatically create patches
for all the loops that are related to the
inner parting lines.
Lesson 3: Parting
36
Process: Runoff Surfaces Runoff surfaces are surfaces that extend from the edge of the product beyond the
insert boundaries. These surfaces, along with the core and the cavity surfaces are
used to split the insert blocks to form the impression.
Introducing:
Run-off Surface.
Run-off surfaces allows for easy creation of the runoff
surface. It provides different methods of runoff surface
creation, so you can choose the method that suits the
situation.
Where To Find It: Click Core/Cavity Builder , Utilities, Run-off
surface on the IMOLD toolbar
OR
Click Run-off surface from CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Utilities, Run-off surface.
IMOLD provides 4 methods creating the run-off surfaces. A brief description of each
follows.
Introducing:
Loft: This requires selection of a reference plane and the
edges for which you wish to create the runoff surfaces.
The surfaces created are associative to the selected
edges. You can use this method to create run-off surfaces
for all types of parts.
Radiate: This requires selection of the edges that you
wish to create the run-offs for. A single surface is created
from the selected edges. The surface generated might be
more complex than the one that is generated using Loft
surface. The surface is associative to the edges.
Ruled Surface: This method can only be used on a closed
loop of edges. It creates surfaces that are similar to loft
surfaces, but they are non-associative. This method can
be used on imported parts and on parts that are very
complex as the surfaces created by this method
regenerate faster.
Angular radiate: This method allows you to create a
draft angle between the cavity and core inserts in order
for an easier parting
Where To Find It: All the runoff methods described above can be found
under Methods in the Run-off Property Manager page.
Introducing:
Parting Line tools
Parting line tools allow easier selection of the edges that
you wish to create the runoff surfaces for. If the core and
cavity faces have been identified, Auto search can search
the parting edges on the part automatically. If you want
more control, you can use Sequential search.
Where To Find It: Under Parting line tools on the Run-off Surface
Property Manager page.
IMOLD V8
37
12. Create run-off surfaces.
Click Run-off surfaces on CCB toolbar.
Under Methods, select the Ruled surface option.
Expand Parting line tools , click Auto
search.
All the parting edges are automatically searched and added to the list.
Under the Entities group box, change the distance to 50 mm.
Click OK to create the surfaces.
Lesson 3: Parting
38
Process: Create Inserts.
Introducing:
Insert Creator
The Insert Creator enables you to easily create inserts
based on the part size. You can choose to create the insert
based on the part origin or the assembly origin.
Where To Find It: Click Core/Cavity Builder , Insert Creator on the
IMOLD toolbar
OR
Click Insert Creator from CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Insert Creator.
13. Select insert size.
Click Insert Creator on the CCB toolbar.
Under Ref Origin drop down group box, select Assembly Origin and
for Insert Type, select the Rectangular option.
Click the Gap Parameters group to
expand it.
Click to select X-Balance and Y
Balance to create a balanced insert.
Under Parameters, change the
parameters to:
L = 75.
W = 85.
Z1 = 36.
Z2 = 36.
Click OK to create the inserts.
IMOLD V8
39
Process: Copy Surfaces.
Introducing:
Copy Surfaces
Copy Surfaces allows you to copy all the surfaces
belonging to the core or to the cavity along with the
associated patches and runoff surfaces directly to the
respective insert. All the surfaces can be selected
automatically or you can select them from the Feature
Manager or the graphics area.
If the copied surfaces form a closed surface, the inserts
are automatically cut with the surfaces as well.
Where To Find It: Click Core/Cavity Builder , Copy Surfaces on the
IMOLD toolbar
OR
Click Copy Surfaces on the CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder,
Copy Surfaces.
14. Make the part the active document.
From the SolidWorks menu,
select Window. From the list of
active windows, select
to make it
the active document.
15. Copy surfaces to core.
On the CCB toolbar, click Copy Surfaces .
Under Destination group box, select the Core option and leave the
other options as default.
Click OK to copy the surfaces and
split the core insert.
Lesson 3: Parting
40
16. Make the part the active document.
Use the SolidWorks Window Menu.
17. Copy surfaces to the cavity.
On the CCB toolbar, click Copy Surfaces .
Under Destination, select the Cavity option.
Some of the patch surfaces are not required to be copied to the cavity. We can
specify which surfaces are not to be copied using the Face Deselection selection
box.
18. Deselect the patch surfaces.
Expand the Face Deselection box by clicking it
.
Select the three patch surfaces on the core side.
19. Complete the copy.
Click OK to copy the surface to the cavity insert.
IMOLD V8
41
The cavity insert will not be split because of the hole in the cavity surface. We will
use IMOLD’s Patch Holes utility to close the hole and split the insert using
SolidWorks.
20. Delete the hole.
Right-mouse click on the feature CavitySurface-Knit and select show
to un-hide the surface.
Click Core/Cavity Builder , Utilites, Patch Holes on the IMOLD
toolbar.
Under Methods, select the Delete Hole option.
Select the face highlighted.
Click OK to delete the hole.
Lesson 3: Parting
42
21. Split the cavity insert manually.
From the SolidWorks menu, select Insert, Cut, With Surface.
Select the Delete Hole feature.
Flip the direction of the cut as indicated
Click OK to insert the cut.
Hide the surface body (DeleteHole1).
22. Save the project
On the IMOLD toolbar, select Save ,
Save Project...
IMOLD V8
43
Side Cores IMOLD incorporates a Sidecore creator that aids in the rapid and easy creation of side
cores. As many side cores as needed can be automatically added to the impression
assembly at any stage of the design. Existing side core parts can also be used.
Introducing:
Side Core Creator.
The Side Core Creator helps to create side cores quickly
and easily. It has functions for copying previously
identified side cores to inserts, updating existing surfaces
and so on.
Where To Find It: Click Core/Cavity Builder , Side Core Creator on
the IMOLD toolbar
OR
Click Side Core Creator on the CCB toolbar
OR
From the IMOLD menu, select Core/Cavity Builder, Side
Core Creator.
Process: Create the side core.
23. Extract the side core faces.
Click Core/Cavity Builder , Side Core Creator on the IMOLD
toolbar.
Select the face shown as the
Seed Face.
Click the Additional faces
box to activate box and select
the face shown, 3 patched
surfaces and the boundary.
Click OK to copy the side core faces.
Lesson 3: Parting
44
A new part called is inserted in the impression assembly.
This part contains a surface body corresponding to the side core.
To complete the side core insert, we will create the insert profile using SolidWorks.
24. Save the project
On the IMOLD toolbar, select Save , Save Project...
25. Hide the cavity insert and the product.
In the FeatureManager design tree, select the cavity insert, right-click
and select Hide.
Repeat the hide for the product .
IMOLD V8
45
26. Create the sketch for the side core insert.
Edit the part in context. Select the side
core part, 1000_Switch Cover Derived_Sidcore1 and click Edit
Component on the Assemble Command Manager.
Start a sketch on the face of the core insert as shown.
27. Convert the entities from the side core
Complete the sketch as shown on the right.
Exit the sketch .
Lesson 3: Parting
46
28. Extend the surface body.
Make the side core the active document by opening the part
Extend the surface, so that it extends beyond the sketch.
From the SolidWorks menu, select Insert, Surface, Extend…
.
Select the edge shown.
Under End Condition, select the Distance
option and change the value to 10mm.
Click OK to extend the surface.
29. Complete the side core insert.
From the SolidWorks menu, select Insert, Boss/Base, Extrude…
Select the sketch from steps 26 and 27.
Select the Up to surface End Condition.
Select the surface body as the terminating
surface.
Click OK to extrude the sketch.
Hide the surface to better represent the side core.
30. Save the project
On the IMOLD toolbar, select Save , Save Project...
IMOLD V8
47
31. Toggle.
Toggle back to the main assembly, click Edit Component and unhide
the cavity.
Sub Inserts. An optional module, the SubInsert Designer is a powerful tool to create sub inserts.
Introducing:
Subisnert Designer.
The SubInsert Designer helps to design subinserts
rapidly. Rectangular, round or any other shape of
subinserts can be created. Flanges can be added as well..
Where To Find It: Click SubInsert on the IMOLD toolbar
OR
From the IMOLD menu, select Sub Insert.
This part will need a sub insert to make the slots in the front of the part. Another
sub-insert is needed to mold the lettering on the part. We will see how to create the
sub inserts for the slots.
32. Make the cavity insert the active document.
Open part . Toggle to Hidden Lines
Visible mode for a clearer view.
33. Create the sub insert for the slots.
On the IMOLD toolbar, select
SubInsert , SubInsert
Creator.
Under Insert Shape, select the
Rectangular option and uncheck
the Pocket box.
Lesson 3: Parting
48
Select the edges shown.
A graphical preview of the sub insert will
be displayed.
Expand Position and Size , change the
value in L to 16 and W to 7.0.
Under Flange Items,click Create Flange .
Select the parameters
as shown.
Click OK to close the
Flange Parameters
window.
The preview of the
subinsert shape is
displayed.
Click OK to create the subinsert.
34. Save the project
On the IMOLD toolbar, select Save , Save Project...
Note: Other sub inserts can be created as an exercise.
IMOLD V8
49
Process: Using Split Wizard
Introducing:
Split Wizard
IMOLD Split Wizard provides a step-by-step first pass
tool to split products. This can be used as an initial step to
quickly and easily split products.
Where To Find It: Click Core/Cavity Builder , Split Wizard on the
IMOLD toolbar
OR
Click Split Wizard on the CCB toolbar.
OR
From the IMOLD menu, select Core/Cavity Builder,
Split Wizard.
35. Select Split Wizard
From IMOLD toolbar, click Core/Cavity Builder , Split Wizard…
A step-by-step wizard based interface will appear to guide through the
tooling split.
36. Define Parting Line
As the first phase of the Spilt Wizard, we need to define the parting
line. This can be done automatically by clicking the Auto button.
Should the parting lines be not as what the designer wants it to be,
you can click the Standard button.
This option gives the designer more performance and at the same
time flexibility.
Lesson 3: Parting
50
Should the loops of the inner parting lines or outer parting lines are
not closed, the Split Wizard will prompt you to highlight the edges that
are not closed.
37. Defining the Parting Face
From the Parting Line tab, click Next button to activate the Parting
Face tab.
Allows you to identify cavity and core faces automatically. If parting
lines were completed, the check box will automatically be checked.
The Standard option gives the designer added
flexibility to move the core and cavity faces.
Upon completing the Parting Face phase, click the Next button to
proceed to the Patch phase.
38. Automatic Patch
Allows you to automatically patch all holes in the part by just clicking
on the Auto button.
39. Automatic Run-off
Allows you to automatically create run-off surfaces. You have the
flexibility again to use other methods of creating the run-off surfaces
by selecting the Standard button.
40. Automatic Insert Creator
Allows you to automatically copy cpre and cavity, patched, and run-off
surfaces and knit them together in order to cut with an insert box that
is automatically crated. You can choose whether you want a
rectangular or circular inserts and followed by clicking the Auto
button.
However, if the process does not successfully create the desired
inserts, you always have the flexibility to manually do it by selecting
the Standard button or select the Copy surface button to manually
choose which faces to copy.
51
Lesson 4 Layout and Feed System Design
Upon successful completion of this lesson, you should be able to:
Complete a layout of a mold design
Select and locate a gating system
Select and locate a running system
Lesson 4: Feed System Design
52
Overview In this chapter, we will explore how the user is able to create and edit a Layout,
Gate Design, and Runner Design. This design will be a balanced two-cavity mold
with an S shaped runner system using edge gates to fill the parts. This module
makes the development of these portions of the design very simple and effective.
Highlights Layout Design – IMOLD offers different layout options for the user to create the
layout they desire.
Editing The Layout – IMOLD offers tools to manipulate and move components of
the layout with ease.
Gate Design – The software offers many different styles of gates the user may use
to properly gate the part or parts.
Runner Design – This tool offers ways to design and locate runner systems.
Process: Adding and Editing a Layout The parameters are defined by the user in order to create the proper layout. After
the layout is created, there are editing tools that enable user to easily manipulate the
layout to fit specific design needs. In this example, we will add a two-cavity layout.
Introducing:
Adding A Layout
The Add Layout function of the Layout Designer provides
the user options to choose a type of layout, its orientation,
and the specified number of cavities. The parameters for
locating each instance are based on the number of cavities.
Where To Find It: On the IMOLD toolbar, click Layout Designer , Add
Layout from the fly-out menu.
-OR-
From the SolidWorks menu, select IMOLD, Layout
Designer, Add Layout…
Introducing:
Modifying A Layout
The Modify Layout function of the Layout Designer offers
the user editing options.
You can choose to either edit the current layout or
transform an impression.
Where To Find It: On the IMOLD toolbar, click Layout Designer , Modify
Layout from the fly-out menu.
OR
From the SolidWorks menu, select IMOLD, Layout
Designer, Edit Layout…
IMOLD V8
53
1. Load the Project
Open the project.
2. Activate the Layout Designer
Click Layout Designer , Add Layout…
3. Add a layout
Choose Balanced layout type.
Choose Horizontal
orientation.
Choose 2 Cavities for the number of
cavities layout. Check the Preview part
option to preview the part in the graphics
area.
With a two-cavity layout, only one distance needs to be determined.
Enter 20mm for A distance. This will
allow the inserts to be interchangeable.
The preview updates to show the new
layout.
Click OK to create the layout. Hide the products.
Note: Parameter Options allows you to choose
the distance of the layout from either the
boundary of the inserts or from the origin of the
part.
Lesson 4: Feed System Design
54
Process: Adding Corners to the Inserts Corners are often added to the tooling inserts for better fit. In IMOLD V8 filleting the
outside corners of the inserts can be done automatically.
Introducing:
Adding Corners to
Layout
The Create Insert Corner function automatically adds
corners to the inserts in the layout.
Where To Find It: On the IMOLD toolbar, click Core/Cavity Builder ,
Create Insert Corner…
OR
From the SolidWorks menu, select IMOLD, Core/Cavity
Builder, Create Insert Corner…
4. Create Insert Corners.
From IMOLD toolbar, click Core/Cavity Builder , Create Insert
Corner...
The dialog corner number are
labeled in co ordinance to the
front view of the design
layout and the type of corner
styles are chosen through the
radio option.
In this exercise, choose the
fillet the four corners a radius
of 8 mm and uncheck the
pocketing parameters
.
Click on the Execute button.
Because this the inserts are two equal impressions and we are trying
to create corners on different sides of each impression, a message
prompts you to auto-create configurations to ensure that the earlier
corner parameters are carried out.
Click OK to create new configurations.
IMOLD V8
55
5. Result.
Corners are automatically added to the inserts.
6. Save the project
On the IMOLD toolbar, select Save , Save Project...
Process: Add and Modify Gates We will now add the gates to the impressions and make some modifications to them.
We will discuss the types of gates available and the techniques to locate them as well
as the modification tools available.
Introducing:
Add Gate
The Add Gate provides a library of common gate types with
parameters that can be controlled by the user. After the
gate type and parameters are set, there are options to
locate the gate and its direction.
Where To Find It: On the IMOLD toolbar, select Feed Designer , Gate
Designer, and Add Gate...
OR
From the SolidWorks menu, select IMOLD, Feed Designer,
Gate Designer, Add Gate…
Introducing:
Create Point
Create Point uses SmartPoint to create 3D points on an
edge or a face "on the fly".
Where To Find It: In the Add Gate Property Manager, click Create Point
button in the Position group.
7. Start Feed Designer to insert gate
On the IMOLD menu, select
Feed Designer , Gate
Designer , Add Gate…
Lesson 4: Feed System Design
56
8. Select the position of the gate.
Zoom in and select the midpoint of the edge shown.
The midpoint can be selected by moving the cursor along the edge
until the shape of the cursor changes to . Then, click the left
mouse button to select point.
TIP: Change the display mode to Shaded to make the selection
easier.
9. Define Gate Parameters
Select Gate type=Edge
Expand Parameter group
and modify
the parameters as shown on the right.
The preview will show and update as
the parameters are changed, reflecting
how the gate will shape.
Under the Position group, select the
Cavity side option.
IMOLD V8
57
10. Rotate the Gate
Under Direction group, enter
90 deg so that the gate is
oriented as shown, flip
direction is necessary.
11. Add the gate
Click OK to add the gate.
The gate is placed on both the impressions because the Copy to
cavities option under the Gate Type group is selected.
Process: Add and Modify Runner System The last process, we will examine how to add and then modify a runner system. In
this design, it will be a balanced S-shaped runner. However, before we can continue
to create the runner we will first create runner blocks between the instances of the
layout.
Introducing:
Modify Gate
The Modify Gate offers tools to change the size and position of
a selected gate.
You can also copy the gate to all cavities, delete the gate and
subtract the gates from the inserts.
Where To Find It: On the IMOLD toolbar, click Feed Designer , Gate Designer, Modify Gate… from the fly-out menu.
OR
From the SolidWorks menu, select IMOLD, Feed Designer,
Gate Designer, Modify Gate…
Introducing:
Transform Gate
Transform Gate will allow the user to move, rotate and copy
the selected gate.
Move will simply locate the selected gate to the new location.
Copy will copy the selected gate to the new user defined
location.
Rotate will re-orientate the selected gate to user defined
orientation.
Copy to all cavities will make a copy of the selected gate to
every instance of the layout in the same orientation as the
original. This is very useful when there is large number of
instances within a layout.
Where To Find It: On the IMOLD toolbar, click Feed Designer , Gate
Designer , Transform Gate… from the fly-out menu.
OR
From the SolidWorks menu, select IMOLD, Feed Designer,
Gate Designer, Transform Gate…
Lesson 4: Feed System Design
58
Introducing:
View Manager
The View Manager function provides users with
visualization tools to assist them in designing the mold
much easily. These tools include Show/Hide mold
components and Turning On/Off transparency of the
mold components.
Where To Find It: On the IMOLD toolbar, click View Manager .
OR
From the SolidWorks menu, select IMOLD, View
Manager
12. Hide the cavity inserts
On the IMOLD toobar, select View
Manager , Show/Hide…
Click to unselect the Cavity
options in the View Manager
window.
Click Close to close the View
Manager dialog.
Introducing:
Delete Gate
The Delete gate functionality of the Feed Designer allows you
to delete either a single gate or all the gates in the feed system.
If the gate(s) is subtracted using the Auto-subtraction
function, the cavities associated with the gate are also deleted.
Where To Find It: On the IMOLD toolbar, click Feed Designer , Auto
Delete...
-OR-
From the SolidWorks menu, select IMOLD, Feed Designer,
Auto Delete…
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59
13. Insert A New Part
Verify the top-level assembly is the active window.
From the SolidWorks Insert menu, select Component, New Part
.
Select the higher of the
parting surfaces,
highlighted on the right as
the location of the new
part.
14. Sketch Profile
View Normal To the surface.
Sketch a Rectangle filling the gap between
the instances.
Click to accept and exit the sketch.
15. Extrude Runner Block
Extrude the rectangular sketch using the
Up To Surface end condition
and select the Bottom face on one of the
core parts as the terminating surface.
Click OK to create the extrusion.
Click Edit Component on the CommandManager to toggle back to
the main assembly
.
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60
16. Hide the 1000_Core and Show
the 1000_Cavity
Use the View Manager .
Later click Close to close the View
Manager dialog.
17. Insert A New Part.
From the Insert menu, select Component, New Part
.
Select the lower parting face (as shown) of the cavity insert as the
location of the new part.
18. Sketch Profile
View Normal To the surface.
Sketch a Rectangle filling the gap between the
instances just as was done for the core side.
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19. Extrude Runner Block
Extrude the rectangle using Up To Surface end condition
.
Select the Top face on one of the cavity parts as the terminating
surface.
Click OK to create the extrusion.
Click Edit Component on the CommandManager to toggle back to
the main assembly
.
On the FeatureManager design tree, right mouse click and select
rename on the new parts created and rename part to
and .
Use the View Manager to show the core.
20. Save the project
On the IMOLD toolbar, select Save , Save Project...
Introducing:
Smart Point
The Smart Point function allows users to create
points by entering the coordinates or with respect to
existing geometry in the part.
The point can be created in either the current
document or a selected part.
Where To Find It: On the IMOLD toolbar, click Smart Point .
OR
From the SolidWorks menu, select IMOLD, Smart
Point…
21. Hide the runner blocks
Right mouse click on the runner blocks and select Hide component
.
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62
22. Add runner location points.
On the IMOLD toolbar, select Smart Point .
Select the point shown below.
In the Smart Point dialog, under Ref Coordinates
group box, change the value in the box to -6.
Click Create to create the point. Repeat the above
step for the other impression.
Note: The Ref Coordinates value in box should be 6.
Click Cancel to close the Smart Point dialog.
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Introducing:
Add Runner
Add Runner offers tools to create a runner system. The
user may choose to add a linear, S shape or a spline
runner and locate it with different options.
Where To Find It: On the IMOLD toolbar, click Feed Designer Runner
Designer, Add runner…
OR
From the SolidWorks menu, select IMOLD, Feed
Designer, Runner Designer, Add runner…
23. Select runner path and section.
On the IMOLD toolbar, select Feed Designer , Runner Designer,
Add runner…
Select Path Type = HSShape.
Expand the Path parameters group box
and modify the parameters as shown:
Select Section Type=Circle, Section
Parameters: D=5
Introducing:
Runner Path and
Section
The Runner Path determines the shape of the runner. The
Section is the cross section of the runner. Choose the
best combination of the path and section for the individual
design.
Where To Find It: Under Runner Type on the Add Runner tab in the Feed
Designer dialog.
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64
Select runner start and end positions and add runner.
Under Position, select the points created in step 22.
The runner path preview.
Click OK to create the runner.
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65
24. Add short runners to connect the runner and left gate.
On the IMOLD toolbar, select Feed Designer , Runner Designer,
Add runner.
Select Path Type = Linear.
Expand Path Parameters and change
value to 2.
Select Section Type=Circle, Section
Parameters: D=4
25. Add short runner.
In Position group, select the start and end
points of the left impression as shown.
Click OK to add the runner.
TIP: Select the point on the gate as the
start point.
Repeat the above steps to create runner for the right impression.
26. The result.
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66
Introducing:
Modify Runner
Modify Runner provides tools to edit the path and section
parameters of the runner after they are created. You can
also rotate, move or copy the entire runner branch.
Where To Find It: On the IMOLD toolbar, click Feed Designer , Runner
Designer, Modify runner…
OR
From the SolidWorks menu, select IMOLD, Feed Designer,
Runner Designer, Modify runner…
The short runners created are overlapping with the gates. To
prevent this, we will edit the extension parameters of the branch.
27. Modify the Runners.
Change the view to the Front standard view.
Click Feed Designer , Runner Designer, Modify runner…
In Runner selection group, choose
the left short runner.
Change the Extension to 1 and
Section Parameters to 3.5.
Click the pushpin button to keep the PropertyManager active.
Click OK to update the changes.
28. Modify the other branch.
In Runner selection group, choose the right short runner.
Change the Path parameter: Ext=1, Section parameters: D=3.5.
Click OK to update the changes.
Click Cancel to exit Feed Designer.
Note: We have created an unbalanced runner to demonstrate how configurations can
be used.
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29. Save the project
On the IMOLD toolbar, select Save , Save Project...
30. Close Project.
Use Project Control , Close Project… to close all the
project files.
Introducing:
Delete Runner
The Delete runner functionality of the Feed Designer
allows you to delete either a single branch or all the
entire runner part.
Where To Find It: On the IMOLD toolbar, click Feed Designer , Auto
Delete…
OR
From the SolidWorks menu, select IMOLD, Feed
Designer, Auto Delete…
68
Lesson 5 Moldbase Design
Upon successful completion of this lesson, you should be able to:
Load a moldbase
Add screws
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Overview IMOLD offers a unique 3D-moldbase module, which automatically creates parametric
standard moldbases, from manufactures like HASCO® and DME® just to name a
few. The Moldbase Designer allows the users to load standard moldbases, customize,
and create new moldbases specific to your needs. A preview is available to enable
the user to choose the moldbase size even before loading. In this chapter, we will
discuss how the moldbase designer works and add a moldbase to our existing design.
The Intelligent Screws module allows screws to be added by selecting the location of
the screw. The program automatically calculates the screw length and creates the
holes for the screw.
Highlights Load Moldbase – IMOLD offers many vendors, types, and sizes of moldbases to use
in a mold design. The preview makes the size selection very easy.
Thickness Changes – With each design it may be necessary to manipulate the
thickness of mold plates. It is simple and effective in IMOLD.
Size Changes – The size of the moldbase may need to change during the design.
The Moldbase Designer allows the user to select another size of the same Moldbase
type.
Component Locations – The locations of components such as screws, guide pins,
support pillars, etc. may need to be changed. IMOLD makes it very simple to change
location of components to fit specific and individual design needs.
Adding Screws – Screws can be added to the mold assembly by defining locations
and the plates in which they are to be added.
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70
Process: Loading a Moldbase The Moldbase Designer helps designers to select and design the mold base from a
selection of popular vendors and a variety of sizes. It allows a 3D preview of the
mold base that you have selected before you even load it into the design and allows
modification after you have loaded in the mold base.
These mold bases are parametrically built from popular vendors within IMOLD to
make it easily available. Modifications, like adding in additional plates, can be made
to the mold base. The Moldbase Designer also has capabilities for customizing mold
bases
Introducing:
Add Moldbase
Add Moldbase offers a wide range of moldbases for the user to
choose. This includes a library of different vendors, types and
sizes of moldbases. Some vendor libraries include HASCO®,
DME®. The user simply selects the desired vendor from the list.
Where To Find
It: On the IMOLD toolbar, click Moldbase Designer , Add
Moldbase…
OR
From the SolidWorks menu, select IMOLD, Moldbase
Designer, Add Moldbase…
1. Load the Project
Load the project from the Chapter 5
folder through Project Control.
2. Design a Moldbase
Click Moldbase Designer , Add
Moldbase…
3. Choose a moldbase.
Select the parameters as shown:
A preview showing the selected moldbase
size in relation to the layout is displayed
on the graphic area.
Introducing:
Define
Thickness
Define Thickness will offer a preview from the side view that
makes it easy to determine plate thickness values related to the
inserts. You can enter the thickness of the plates here. A plate
value set to 0 means the plate does not exist and it is
suppressed. The plate will be unsuppressed and appear in view if
a value is added.
Where To Find
It:
In the Create Moldbase Property Manager, click to select the
Define Thickness group and click the Thickness button.
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4. Change Plate Thickness
Select the Define Thickness check
box to expand the group.
Click Thickness.
In the Edit Thickness dialog box, change the following plates
to the respective values:
Check to select Custom plate thickness for the C Plate and
change the thickness to 76mm
Click .
The Edit Thickness
window is closed and the
preview is updated.
5. Load Moldbase Click OK to load
moldbase assembly
into project.
Lesson 5: Moldbase Design
72
Process: Purge
The Moldbase Designer , Utilities offer tools to simplify and complete the
design of your moldbase. The Purge tool will simplify your moldbase by searching
and deleting the plates not used in the design. The pocket tool will create the
pockets for all the mold components. In the following steps we will simplify our
moldbase, create inserts pocket using the pocketing tool.
Introducing:
Screw Positions
Screw Positions provides the location dimensions of the top and
bottom screws, and the ejector screws. These can be defined by
the user to satisfy design needs. To obtain an image showing the
dimensions, click the View Bitmap button.
Where To Find
It:
On the IMOLD toolbar, click Moldbase Designer , Modify,
Screw Positions…
OR
From the SolidWorks menu, select IMOLD, Moldbase Designer,
Modify, Screw Positions…
Introducing:
Pin Positions
Pin Positions provides the location dimensions of the guide pins
and return pins. To obtain an image showing the dimensions, click
the View Bitmap button.
Where To Find
It:
On the IMOLD toolbar, click Moldbase Designer , Modify ,
Pin Positions…
OR
From the SolidWorks menu, select IMOLD, Moldbase Designer,
Modify, Pin Positions…
Introducing:
Utilities
The Utilities provides more parameters to change the Top
Clamping Plate parameters and ejector plate parameters. Also
other tools such as Purge, Pocket, and Stock size options are
available.
Where To Find
It:
On the IMOLD toolbar, click Moldbase Designer , Utilities.
OR
From the SolidWorks menu, select IMOLD, Moldbase
Designer, Utilities
Introducing:
Transparency
The Transparency option will make the mold base plates
transparent.
Where To Find
It:
On the IMOLD toolbar, click Moldbase Designer , Utilities,
Transparency…
OR
From the SolidWorks menu, select IMOLD, Moldbase
Designer, Utilities, Transparency…
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73
6. Add Transparency.
Click Moldbase Designer
,
Utilities, Transparency…
Under Operations, select the Add
options.
Under Colors, select the Default option
Click OK to apply transparency
NOTE: Since IMOLD 2006 transparency is added to the moldbase assembly
automatically. This user-driven enhancement reduces mouse travel and clicks.
Introducing:
I-Screws
The I-Screws (Intelligent Screws) module makes the selection and
placement of fasteners such as socket head cap screw and flat head
screw simple and effective. It is the focus of Intelligent Screws to
simply place the screw and the necessary pocket or counter bore is
added automatically. The user must select the type of screw and
size, location and the plates to pocket and the screw is added to the
design.
Where To Find It: On the IMOLD toolbar, click Intelligent Screws , Add Screw…
OR
From the SolidWorks menu, select IMOLD, Intelligent Screws,
Add Screw…
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74
7. Insert Fastener Layout Sketch
Open the part
named
.
On the face shown, start
a new sketch .
Complete the sketch as
shown by offsetting 8mm from the edges.
8. Save the project
On the IMOLD toolbar, select Save
, Save Project...
9. Select Screws.
On the IMOLD toolbar, select
Intelligent Screw , Add screw.
Select the screw as shown:
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75
10. Add screws for the cavity inserts.
Select the top face of the A plate as the Placement face.
TIP: You can hide the top clamping plate (TCP) to make the
selection easier.
Click to select and expand the Select Sketch group
From the graphics area, select the sketch created in step 7.
The preview of the screws is displayed.
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76
Activate Last Plate , select the instance of
the cavity insert from which the sketch is selected (
). By selecting the last plate option, the length of the
screws will be automatically determined.
Click to select Copy to all impression.
This copies screws to all instances of the impression assembly.
Click OK to insert the screws for the cavity inserts.
11. Add screws for the core inserts.
On the IMOLD toolbar, select Intelligent Screw , Add screw…
Select the Select by component
option.
From the graphics
area, select one of
the screws added
in the previous
step as
Reference
component.
Active Placement face group and select the bottom face of the support
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77
plate as the placement face.
Click to select and expand the Select Sketch group
From the graphics area, select the sketch created in step 7 and select
the instance of the core insert below the sketch as the Last Plate
( ).
TIP: You can hide the plates or pick from the Design Tree to make
the selection easier
Click to select Copy to all impression.
Click OK to insert the screws for the core inserts.
12. Add other screws.
Add screws for the core and cavity runner blocks.
Lesson 5: Moldbase Design
78
13. Unhide/Show
Show all hidden components.
14. Save the project
On the IMOLD toolbar, select Save , Save Project...
15. Finished.
Save and close the project.
79
Lesson 6 Slider and Lifter Design
Upon successful completion of this lesson, you should be able to:
Select and position slider body
Select and position lifter body
Create Pockets.
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80
Overview: In this chapter we will discover what is needed to remedy undercut situations that
need a lifter or slider mechanism. This chapter also covers ways to create pockets for
sliders and lifters.
Highlights: Slider Creation – The slider module walks the user, step by step, through selections
to properly locate the slider body. The user will then be given the library of slider
bodies to choose from and its accessories.
Lifter Creation – The lifter module provides steps for the user to locate and choose
the proper lifter body for the mold design.
Create Pockets - Pocket out the material from the moldbase plates intersecting with
the sliders and lifters.
Process: Slider Design This design requires the use of a slider mechanism to mold the three slots on
the sidewall of the part. We will now use the Slider Designer module to make the
slider body design process simple and effective.
Later, we will create the profile for the slots directly on the slider body.
Introducing: Slider
Designer
IMOLD’s Slider Designer module first prompts the user
for a set of parameters helping order to properly locate
the Slider Body assembly. Next, the user chooses from the
available library the type and size of the slider body and
accessories. User has the choice to insert Standard or
Generic slider from the library. Also, the module offers
editing tools that make it easy to facilitate for change.
Below are the parameters that need to be define:
Pull Direction – This selection determines the direction
that the slider will move.
Base Plane – This plane selection determines the Z
location to the bottom of the slider body.
Cam Pin Position Plane – This plane selection controls
the location to the top of the cam pin.
Slider Origin – This selection determines the location of
the slider in the XY.
D_pull - This parameter determines the distance of the
slider face from Slider Origin.
Angle
Desired Stoke
Where To Find It: On the IMOLD toolbar, click Slider Designer , Add
Slider, Standard/Generic
OR
From the SolidWorks menu, select IMOLD, Slider Designer,
Add Slider, Standard/Generic
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81
1. Open the project.
Open the Switch Cover project from the Chapter6 folder.
2. Hide the moldbase.
Make the top assembly the active document.
Using View Manager, hide the movable half and fixed half of the
moldbase and the components.
3. Insert Standard Slider Type.
On the IMOLD toolbar, select Slider Designer,
Add Slider,
Standard…
One impression assembly is automatically hidden.
4. Pull Direction.
Under Pull Direction, select the face shown.
An arrow indicates the direction
of the slider movement.
5. Base Plane
Select the face shown as the
Base Plane.
6. Select the slider origin
Select the midpoint of the
edge shown as the slider origin.
A preview of the slider is
displayed.
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82
7. Select the slider unit.
Select the slider as shown:
Expand Select size group
and select the
following slider assembly size.
8. Change pin length.
Under Components, select the Pin
component in the list.
Under Select size, change the Pin length
to 75.
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9. Change the base plane offset.
Under Select Parameters, change the value of the Base Plane
offset to –3.5mm.
10. Create Slider Click OK to create the
Slider.
The slider assembly is added
to the impression assembly.
Lesson 6: Slider and Lifter Design
84
Introducing:
Edit Slider
The Edit Slider function gives the user options to
change parameters of components specified earlier to fit
design changes. You change either the size of the
position of the slider.
Where To Find It: On the IMOLD toolbar, click Slider Designer , Edit
Slider, Size/Position…
OR
From the SolidWorks menu, select IMOLD, Slider
Designer, Edit Slider, Size/Position…
Introducing:
Delete Slider
Delete slider deletes the sliders from the mold
assembly. Optionally, the parts can also be deleted from
the hard disk as well.
Where To Find It: On the IMOLD toolbar, click Slider Designer , Delete
Slider…
OR
From the SolidWorks menu, select IMOLD, Slider
Designer, Delete Slider…
Process: Create Slider Pockets – Automatic Pockets for the sliders can be created in a variety of ways – by individual
extrusions in the plate, subtracting the components and then modifying the
components and so on. IMOLD provide the tools to automatically pocket the sliders
from the moldbase plates.
Introducing:
Pocket Manager
The Pocket Manager function creates pockets for all
components in the Automatic mode or for selected
components in the Selection mode.
Where To Find It: On the IMOLD Toolbar, click IMOLD Tools , Pocket
Manager, Automatic/Selection
-OR-
From the SolidWorks menu, select IMOLD, IMOLD Tools,
Pocket Manager, Automatic/Selection
11. Automatic Pocketing.
On the IMOLD Toolbar, click IMOLD
Tools , Pocket Manager,
Automatic...
12. Select Slider
On the Automatic Pocketing menu,
under Pocketing type check the Slider
option.
Click OK to create the pockets.
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Process: Create Slider Pockets - Manual.
One of the best methods to create pockets for an assembly is explored here.
This will make extensive use of SolidWorks top-down modeling techniques. We will
create a part in the slider assembly that corresponds to the shape of the pockets we
want to make. Relating this to the existing geometry in the assembly will ensure
associativity. Any changes to the slider size or position will update the pockets as
well.
This part has been pre-created and placed in the project folder. We will add
geometry to this part.
13. Open the slider assembly.
Open slider1_hasco_slider 1.sldasm.
14. Insert a new part.
From the SolidWorks Insert menu, select Component, New Part…
15. Create pocket geometry.
Start the sketch on the face shown.
Complete the
sketch as shown. All
lines are converted
from existing edges
.
Lesson 6: Slider and Lifter Design
86
Extrude 32mm offset from the selected face.
Click OK to create the feature.
16. Wear plate pocket extrude.
Start a sketch on the face shown:
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87
17. Convert the selected face and extrude up to the face
shown.
Click OK to create the feature.
18. Wedge pocket
extrude.
Start a sketch
on the face
shown:
Convert the
selected face
,
extrude up to face shown and click OK to create the feature.
19. Pin pocket extrude.
Start a sketch on the face shown:
Lesson 6: Slider and Lifter Design
88
20. Convert the selected face
, extrude up to the face shown and click OK to create
the feature.
21. Click Edit Component on the CommandManager to toggle back to
the main assembly
.
On the FeatureManager design tree, right mouse click and select
rename on the new parts created and rename the new part to
.
22. Hide the and Save Project.
On the IMOLD toolbar, select Save , Save Project...
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23. Create pockets in the moldbase.
From the IMOLD toolbar, select
IMOLD Tools , Pocket Manager,
Selection…
Select the part from both
impression assemblies as the Tool
Component from the FeatureManager
tree.
Select the a_plate and b_plate from
the moldbase assembly as the Target
Components:
Choose the Subtract option.
Click OK to create the pockets.
The pockets in the mold plates will need minor touching up using SolidWorks to
complete them. These modifications can be made directly on the plates or the pocket
part can be modified to make these changes.
This can be done as an exercise.
24. Create angle pin hole.
Activate the impression assembly.
Open the
subassembly.
Select part, and
select Edit Part .
Start a sketch on the Top
plane of part
Offset the highlighted edge
0.5mm outwards.
Complete the sketch as shown.
Insert a Revolve Cut.
This line lies
on the axis of the angle pin.
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90
Tidy up the pocket by adding
Fillet to the edges of the cut with
a radius of 1mm.
Click Edit Component on the
CommandManager to toggle back
to the main assembly
.
25. Save the project
On the IMOLD toolbar, select Save , Save Project…
26. Fasten slider components.
Fasten all the components using IScrews . You may need to
create the reference points for the screws. Either create a sketch in
the top assembly or use the Smart point tool to create the
points.
27. Hide components.
Using the ViewManager , hide the moldbase, the sliders and the
components.
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Process: Lifter Creation In the next section we are going to create the lifter assemblies for the mold
design. The Lifter Designer module makes the development of the lifter body
simple. We will first determine the location of the lifter, then select the type of lifter
from the library and add it to the design. The lifter is required to be modified to meet
design needs and we will use the edit functions to complete the design.
Introducing:
Add Lifter
Add Lifter allows the user to define lifter information to
properly locate the lifter body. The following information
must be added:
Pull Direction – The direction selected will tell the
system the direction the lifter will move.
Lifter Origin – This point that is selected will locate the
lifter with relationship to the undercut feature.
d_pull – This option controls exactly where the lifter
blade will be located with respect to the part. A negative
value will place the blade outside the part; a positive
value will place it inside the part.
Blade angle – The angle at which the lifter is placed.
This is generally made so that the desired travel can be
obtained over the ejector stroke.
Required Stroke – The distance moved by the lifter in
the direction of pull for the total ejector stroke.
In the Add Lifter function, user can choose to insert
Standard/Generic lifter for their design needs.
Where To Find It: On the IMOLD toolbar, click Lifter Designer,
Add
Lifter, Standard/Generic.
-OR-
From the SolidWorks menu, select IMOLD, Lifter
Designer, Add Lifter, Standard/Generic.
28. Add a Lifter
On the IMOLD toolbar, select Lifter Designer , Add Lifter,
Standard...
29. Select Pull Direction
Select any edge on a component
of the 1000impression
subassembly to determine the
direction the lifter will move to
eject the part.
Check Flip Direction, if
required.
Lesson 6: Slider and Lifter Design
92
30. Select Lifter Origin
Activate the Lifter
Origin box.
Select mid-point of the
edge shown.
31. Select Lifter
Expand and select the parameters as
shown:
32. Change Blade Parameters
Select Blade from the Component list.
Select these parameters in the
Parameters list and change the values:
W=7
T=5
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33. Change stroke distance.
Under Select Size, change required
stroke to 5mm.
This changes the Ejection distance to
28.3564091, which is within the
maximum ejection stroke of 60mm.
34. Add the lifter assembly. Click OK to add the lifter.
The lifter is added to the assembly.
Introducing:
Trim Lifter
Trim Lifter allows the user to automatically trim the
lifter blades to the shape of the core.
Where To Find It: On the IMOLD toolbar, click Lifter Designer , Trim
Lifter...
-OR-
From the SolidWorks menu, select IMOLD, Lifter
Designer, Trim Lifter...
35. Trim Lifter
On the IMOLD Toolbar, click Lifter Designer , Trim Lifter…
The Trim Lifter menu will appear.
Operations:
Trim – selects operation to trim the
lifter blades.
Undo trim – to undo the previous trim
operation.
Flip side – trim the lifter blade from the
opposite side.
Lesson 6: Slider and Lifter Design
94
Select Options:
All lifters – apply operations selected to all
lifters.
By selection – allows you to select which
lifter blade to trim.
Trim Methods:
By surface – allows user to select a surface
to trim the blades with.
By solid – this method will trim the lifter
blade to the shape of the part. This method
will not be successful should you attempt
to trim the blade at a point where there
exist holes.
Select the options as shown in the figures.
Click OK to trim the lifter blades.
Zoom in and change the display styles of cavity and core to Hidden Lines Visible ,
if can be seen that the lifter profile does not fully lie on the lifter blade. To remedy
this situation, it is necessary to change the lifter angle using the Modify Lifter
functionality of the Lifter Designer.
Introducing:
Modify Lifter
Edit Lifter will allow the user to change any parameter of
any component in the Lifter assembly after it has been
added to the design. You can also change the position of the
lifter.
Where To Find It: On the IMOLD toolbar, click Lifter Designer , Edit
Lifter, Size/Position…
OR
From the SolidWorks menu, select IMOLD, Lifter Designer,
Edit Lifter, Size/Position…
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36. Edit Lifter.
Click Lifter Designer , Edit Lifter, Size…
Select any component of the lifter assembly from the graphics area or
the FeatureManager tree.
Change the Blade angle to 8 and the Required Stroke to 3.5mm.
Click OK to update the change.
The lifter angle is changed and the profile
updates.
37. Change blade width.
Click Lifter Designer , Edit Lifter,
Size…
Select any component of the lifter
assembly.
Under Components, select the BLADE part.
Change W to 4.5225.
Click OK to update the change.
38. Result.
Open the lifter blade, results should be
similar to the one shown:
39. Add Additional Lifters.
You must add an additional lifter for the
other tab feature causing an undercut
situation. (This step does not need to be done in the training, however
it would be done in a real world mold design).
40. Pocket.
You may add pockets for the T Gib component in the ejector retainer
plate. An additional clearance pocket must also be made in the
Support Plate.
41. Save the project
On the IMOLD toolbar, select Save , Save Project... Close the
project.
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Lesson 7 Ejector System Design
Upon successful completion of this lesson, you should be able to:
Choose ejector pins
Customize ejector pin diameters
Modify ejector pins
Trim ejector pins
Pocket ejector pins
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Overview: The Ejector Designer offers a library of ejector pins and sleeves from a
number of different vendors. The user must choose the type of ejector pins and
sleeves that they want to use and position a point (in the plan-view) where the
ejectors are to be placed. We will be adding the necessary ejector pins in the
following chapter to properly eject the part.
Highlights: Adding Ejector – The user must choose a vendor and type of pin/sleeve they would
like to use for the design.
Modifying – It may be necessary to change some parameters to the pin/sleeve, the
modify function will allow the user to do this.
Transforming – The Transform function makes it very simple for the user to move,
copy, or delete an existing ejector pin in the design.
Trimming – It is necessary to trim the pin/sleeve according to the part profile. The
trim functionality the software offers makes this task simple and effective.
Process: Add Ejector Pins This design is going to require the addition of ejector pins to eject the part
properly from the mold. We will discuss first how to Add Ejector, customize (if
necessary), and locate ejector pins.
Introducing:
Add Ejector
Add Ejector in the Ejector System Module will allow the
user to choose a type of ejector pin from different
vendors, such as DME and HASCO. The user is also
provided with the parameters of the ejector pins that
make it simple to customize to fit design needs. After a
pin is selected and parameters defined, the user then
needs to position the pins by simply selecting the desired
locations. The software knows where to seat the ejectors
in relationship with the ejector and ejector retainer plates.
Where To Find It: On the IMOLD toolbar, click Ejector Designer , Add
Ejector…
OR
From the SolidWorks menu, select IMOLD, Ejector
Designer, Add Ejector…
1. Open the Project.
Open the SwitchCover from the Chapter7 folder using Project
Control .
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98
2. Add location sketch.
Open the impression
assembly.
Start a sketch on the
Front plane.
Add two sketch points at
the centers of the circular
bosses.
Exit the sketch and
rename it .
3. Add Ejector Pins.
On the IMOLD toolbar,
select Ejector Designer , Add Ejector…
In the Select Working Assembly window, choose the impression
assembly as the working assembly and click OK.
This will activate
the impression
assembly
automatically.
4. Select Ejector Pins.
Select the pins as shown:
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5. Create ejector location points.
Click Create Point, add two points with the following coordinates:
X =0, Y= 8, Z = 0
X =0, Y= -5, Z = 0
6. Add Ejector Pins.
Activate the Points selection box and select the points created in step
5.
Click OK to insert the ejector pins.
7. Add Ejector Sleeves.
On the IMOLD toolbar, select Ejector Designer , Add Ejector…
In the Select Working Assembly window, choose the impression
assembly as the working assembly and click OK.
On the Add Ejector menu, expand add
sleeve pin option and click Define sleeve
button.
Define the sleeve parameters as shown:
Activate Select Sketch and select the sketch. Preview
of the sleeves is shown.
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8. Add Center Pins.
Scroll back up to the add sleeve pin
option group, click Define pin
button and define the pin
parameters as shown:
Click OK to insert the sleeves
and center pins.
Note: When OK is clicked, IMOLD assembles the selected sleeves and
pins accordingly to moldbase planes. Should you need to change the thickness
of the moldbase plates in the future, the ejector length will be reflected as
well.
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Process: Modify and Transform Ejectors Sometimes it may be necessary to change some parameters on ejector pins
after they have been located or copy/move the pins to a new location. The Modify
Ejector and Transform Ejector make these tasks easy.
Introducing:
Modify Ejectors
Modify Ejector allows the user to choose an existing pin
from the part name list and change parameters of the pin
from a list to fit specific design needs.
Where To Find It: On the IMOLD toolbar, click Ejector Designer,
Modify Ejector…
OR
From the SolidWorks menu, select IMOLD, Ejector
Designer, Modify Ejector…
Introducing:
Transform Ejectors
Transform Ejector provides options for the user to copy
an ejector pin to a specified location. The user can change
the location by defining a new point or by XY translation.
You can also move the ejector point by moving the point
it is associated with in the Mating_Sketch of the ejector
subassembly.
Where To Find It: On the IMOLD toolbar, click Ejector Designer ,
Transform Ejector…
OR
From the SolidWorks menu, select IMOLD, Ejector
Designer, Transform Ejector…
9. Modifying Ejector Sleeves
On the IMOLD Toolbar, select Ejector Designer , Modify
Ejector…
In the Select Working Assembly window, choose the impression
assembly as the working assembly and click OK.
From the graphics area or the FeatureManager feature tree, select
both instances of the Hasco_Sleeve part.
We want to customize the pin to suit the boss diameter (5.5275mm)
of the part.
Select the Custom size option on the
Change to group.
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102
In the Parameters list, select the d1 parameter.
Change the value of d1 to 5.5275
Click OK to modify the sleeve.
Process: Trim Ejectors Once the ejectors are chosen and located properly, they must be trimmed to the
profile of the part. The Trim Ejector offers tools to easily navigate between the
ejector and impression files as well as trimming and pocketing capabilities.
Introducing:
Trim Ejector
Using the Trim Ejector, you can trim the ejectors to the
core profile using either the plastic part (Solid trim) or
the core surface (surface trim). You can also the change
the direction of the surface trim.
Where To Find It: On the IMOLD toolbar, click Ejector Designer,Trim
Ejector…
OR
From the SolidWorks menu, select IMOLD, Ejector
Designer, Trim Ejector…
10. Trim all Pins.
On the IMOLD toolbar, click Ejector Designer,
Trim Ejector…
Select the impression assembly as the working assembly.
Under Select option, select the All Pins
option. This will trim all the pins.
Under Trim Method, select the By
Surface option.
Select the CoreSurfaceKnit feature from
the core insert.
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Under Operations group, select the Trim option.
Click OK to trim the pins.
11. Save the project
On the IMOLD toolbar, select Save , Save Project... Close the
project.
104
Lesson 8 Cooling Design
Upon successful completion of this lesson, you should be able to:
Design cooling channels
Check for interference between cooling channels and other
mold components.
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Overview: This chapter will focus on designing the necessary cooling channels to properly cool
the part. The Cooling Designer module makes the creation of the cooling channels
easy and effective. The user is in complete control of the cooling locations and
parameters through an easy to use dialog box that guides the user through the
creation process.
Highlights: Add Cooling Channels – Adding cooling channels in the Cooling Module is as easy
as selecting an inlet point and specifying the direction and length of the channel.
Modify Cooling Channels – The cooling channels are made of solid geometry. It is
as simple as editing a sketch to edit your cooling channel parameters.
Interference detection – Interference between the cooling channel and other mold
components can be detected.
Process: Cooling Channel Creation Cooling channels must be added to this design to properly cool the part during
manufacturing. The Cooling Designer module makes the development of cooling
channels easy and effective. In this section we will add the necessary cooling
channels using the Cooling Designer module. We will first add cooling to the core
and cavity insert files.
Introducing:
Create Circuit
Create Circuit offers the options to develop cooling
circuits.
Where To Find It: On the IMOLD toolbar, click Cooling Designer ,
Create Circuit…
OR
From the SolidWorks menu, select IMOLD, Cooling
Designer, Create Circuit …
12. Open the Top Level Assembly
Open the SwitchCover project from the Chapter8 folder using Project
Control .
13. Hide Components
Using View Manager , Show/Hide and hide the Fixed half.
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106
14. Create Inlet Location Point
On the IMOLD toolbar, select Smart
Point .
Select the face as shown.
Under ABS Coordinates, change
the coordinates as shown.
Click Create to create the point then click Cancel to close the Smart
Point window.
15. Add Cooling Circuit
On the IMOLD toolbar, select Cooling Designer , Create
Circuit…
Introducing:
Inlet Position
The user must first determine the Inlet Position. The Inlet
Position is the location, where the inlet cooling channel
will be located. If a face is selected as the inlet point, the
system selects the closest point on the face as the inlet
point. If a point is selected, the system adds a relation
between the point and the cooling circuit.
16. Inlet Selection
Pick inlet location point created in step 14.
17. Change direction
Under Direction, select Along Assembly XYZ and select the Along
Y axis option.
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If the arrow is not pointing in
the direction shown, click Flip
Direction.
Introducing:
Draw
The Draw function lets the user determine the length of
the Cooling lines. All the cooling channels that are
connected may be created in one circuit. If the result of
the line is undesirable they may also select Previous,
Undo or Next to make changes.
To create the routing, this function has to be used in-
conjunction with the Direction function to determine how
the cooling channel is channeled.
Where To Find It: Click Draw from the Length group in the Create Circuit
Property Manager.
18. Draw the first cooling segment.
View normal to the Front View.
Under Length, change the distance to
120 mm.
Click Draw.
A preview of the circuit is shown.
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108
19. Draw the next segment.
Select Favorite View on IMOLD
toolbar.
Under Direction, select the Along Z
axis option.
Under Length, change the distance to
45 and click Draw.
Note: the different color of the
previous segment.
20. Draw other lines.
Repeat Step 19 to complete the circuit as shown in the table below
Direction Flip Length
(mm)
Result (All components are
hidden in these pictures for
better view of the circuit)
X No 9.5
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Y No 53
X Yes 48
Y Yes 53
X No 9.5
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110
Z Yes 45
Introducing:
Outlet Position
The user determines the Outlet Position by selecting a
face on the part where the cooling circuit will exit.
21. Outlet Selection
On the IMOLD toolbar, select Favorite View .
Activate the Outlet box.
Select the face shown.
A segment is drawn
connecting the last
segment and the face.
22. Create Cooling Channels
Under Parameters change the
Diameter to 6.
Click OK to insert cooling channel.
Note: If the dimensions of the cooling channel need to be changed, the
3D_Guide sketch can be edited using SolidWorks functions.
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Introducing:
Drill Plug Hole
Drill Plug Hole takes the manufacturing considerations for
the development and design of cooling channels into
complete consideration. The user must select the face that
the drill would enter and the existing cooling channel. The
selected cooling channel will be extended to the selected
drill face.
Where To Find It: On the IMOLD toolbar, click Cooling Designer , Drill
Plug Hole…
OR
From the SolidWorks menu, select IMOLD, Cooling
Designer, Drill Plug Hole…
23. Drilling the plug hole
Hide the moldbase assembly
On the IMOLD toolbar, select Cooling Designer , Drill Plug
Hole…
Select the highlighted face as Plug Face, and the two cylinders under
Cylinder Selection.
Select these channels.
Select this face as the plug face.
TIP: Change to wireframe mode and hide components for better
visuals and selection.
Click OK to extend cooling channel till the plug face.
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112
24. Extend shorter channels.
Extend the other cylinders as shown:
Cylinder faces.
Plug face
Plug face
Cylinder
The result should be similar to the one shown:
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Introducing:
IMOLD Feature
Manager
The IMOLD FeatureManager shows all the components of
the mold, arranged by their functional groups. Using the
Feature Manager, you can:
- Hide/Show certain components
- Open components for editing.
- Save components.
- View or Edit BOM information.
Where To Find It: The IMOLD Feature Manager can be found as one of the
tabs in the Property Manager when the current
document is the mold assembly.
25. Activate IMOLD FeatureManager.
Select the IMOLD Feature Manager tab to
activate the FeatureManager.
26. Open the Cooling Channel
Expand the Cooling Circuit group.
Right-click on 1000_Circuit1 and
select Open from the menu.
The part is made the active
document.
Introducing:
Over Drill
The Over Drill section is focused on adding the extra
distance of the drill as well as the drill point. This can be
done in the part or assembly mode. The user chooses the
cooling channel nearest to the end to extend, adds the
length to extend and selects the over drill button.
Where To Find It: On the IMOLD toolbar, click Cooling Designer ,
Overdrill...
OR
From the SolidWorks menu, select IMOLD, Cooling
Designer, Overdrill…
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27. Create overdrills.
Click Cooling Designer , Overdrill...
In Cylinder Selection group, select these channels as shown.
Click on the graphic areas to select cylinder.
In Parameters, enter the length value 3mm.
Click OK to add the overdrills.
28. Result.
The result should be similar to the one shown:
Close and save the part.
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As the channel on the other impression will have the same dimensions, we will copy
the first channel and mate it in the correct position.
29. Copy Cooling Channel.
Click Cooling Designer , Transform Circuit...
Under Circuit Selection, select the cooling channel. The circuit may
be automatically selected as only one cooling circuit was designed.
Under Operations, select Move and
check the Make a Copy option.
Under Parameters, change the value
of to -95 mm.
Click OK to copy the cooling circuit.
The channel is copied to the other impression.
View of project from back with moldbase, components and ejectors
hidden.
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116
30. Create the cavity side cooling channels.
Create instances of the core channels and mate them in the proper
positions. The result must be similar to this.
Ensure that all circuits are in the Cooling subassembly.
Introducing:
Interference
Detection
The Interference function helps to detect which parts of
the mold are interfering with the cooling circuit. The
function can detect which parts are actually touching and
also which parts are at a specified distance from the
channel.
Where To Find It: On the IMOLD toolbar, click Cooling Designer ,
Interference…
OR
From the SolidWorks menu, select IMOLD, Cooling
Designer, Interference…
Front planes of all circuits are coincident.
The end faces are coincident as well.
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31. Check interference.
On the IMOLD toolbar, click Cooling Designer , Interference...
Select the Check With options as
shown:
Under Interzone tolerance, click
Detect.
No parts are highlighted, which means
no parts are touching the cooling
circuits.
32. Check minimum distance.
Under Interzone tolerance, change
the distance to 3mm.
Click Detect.
6 parts are shown in the
Result area.
Click Show Result to hide all
the parts in the mold, except
those listed.
Change the Interzone
tolerance to 2 mm and click
Detect.
The lifter blades are shown.
Click Cancel to close the
Property Manager.
Note: You can edit the cooling channel to increase the minimum distance if
desired.
33. Show all parts.
Using View Manager , show all the parts in the assembly.
34. Finished.
Save and close the project.
118
Lesson 9 Standard Components
Upon successful completion of this lesson, you should be able to:
Add standard components
Create pockets for the main inserts.
Add standard components to cooling circuits.
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Overview: The Components Gallery offers a wide range of components from different vendors
the user can size and locate. This module has an extensive library of standard mold
components from vendors like Hasco®, DME® and Progressive®, just to name a
few. You can select the component by selecting the parameters. Then, locate the
component and select the plates to pocket. The component is automatically located
at the correct position and the plates are pocketed with the correct dimensions.
Highlights: Add Components – User selects the necessary component by choosing the required
component’s parameters, placement face, and the list of plates to pocket.
Edit Components – If a component has been added, the edit components function
provides a list of components to choose from and the parameters to change.
Create Pockets – The pockets for the main inserts are created automatically from a
sketch in the mold assembly.
Cooling accessories – Components for the cooling circuit like nipples, plugs and o-
rings can be automatically added to the assembly.
Process: Standard Components The Components Gallery module in IMOLD offers a comprehensive list of commonly
used components needed to complete a mold design. The software offers
components from vendors such as DME, Futaba, and National. Users also have the
ability to customize their own components and add them to the list of components
library for future used. In this portion of the chapter, we will go through how to add
standard components for this mold design.
Introducing:
Add Component
The Add Component is a tool that every mold designer
will use. It is a library of common components from a list
of vendors and catalogs. Such components include
locating rings, cooling plugs, support pillars, sprue
bushings, side locks, etc. With the ability to edit,
customize and add components to the library this tools is
very effective and robust.
Where To Find It: On the IMOLD toolbar, click Components Gallery ,
Add Component…
OR
From the SolidWorks menu, select IMOLD, Components
Gallery, Add Component…
Creating location points for components.
We will create sketch points for locating the standard components as and when they
are required. You can create these points either in the top assembly or in any part
under the assembly. In this case, we will create points in the top assembly to simplify
the process.
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120
1. Open the Top Level Assembly
Open the SwitchCover project from the Chapter9 folder using Project
Control .
2. Add Locating Ring
On the IMOLD toolbar, select
Components Gallery , Add
Component…
Select the locating ring as shown:
The locating ring is normally placed in the center of the top_clamp
part.
Click OK to insert the locating
ring.
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3. Add Sprue Bushing
On the IMOLD toolbar, select
Components Gallery , Add
Component…
Select the component as shown.
Under Placement face, select the bottom face of the locating ring.
Under Locating
points, select the
origin of the top
assembly from the
Feature Tree. The
preview will indicate the
direction of the sprue
bush. Flip direction
should you need to.
Click OK to add the
sprue bushing to the
mold assembly.
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122
4. Modify Sprue Bushing.
The head diameter and the length of the sprue bushing are too small
and too short. We need to change them to be bigger by creating a
custom size.
On the IMOLD toolbar, select Components Gallery , Modify
Component…
Select the sprue bushing added in the previous step from the graphics
area or from the FeatureManager.
Under Change to, select the Custom
size option.
Under Parameters, change L to 77
and D=38.
Under Clearance Value, change
CbrDia to 38.5
Click OK to modify the sprue
bushing.
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5. Add Sprue Puller Insert
Use View Manager , View/Hide… to hide the moldbase, sliders,
lifters and ejectors.
On the IMOLD toolbar, select
Components Gallery , Add
Component…
Select the component as shown:
Under Placement face, select the
bottom face of the 1000 Core
Runner Block.
Under Locating point, select the
origin of the top assembly.
Click to select Flip direction.
Select assembly origin as
Locating point.
Click OK to insert the sprue
puller insert.
Show the moldbase using View Manager .
Lesson 9: Standard Components
124
6. Add Ejector Pin.
We will add an ejector pin for ejecting the
sprue.
On the IMOLD toolbar, select
Components Gallery , Add
Component…
Select the component as shown:
Under Placement face, select the ER1 plane under the move_half
subassembly.
Under Locating point, select the origin of the top assembly.
Click OK to insert the ejector pin.
The ejector pin is added to the assembly.
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7. Create sketch for the interlocks.
Open the moldbase assembly.
Create a new sketch on the Front plane of the assembly.
Create sketch points and dimension as shown.
Exit the sketch
Rename the sketch Interlock Location.
8. Add Interlocks.
On the IMOLD toolbar, select Components
Gallery , Add Component.
Select the component as shown:
The points are
coincident to
the edges of
the mold
plates.
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126
Under Placement face, select the face of the a_plate part.
Under Locating point, select the point of the Interlock Location
sketch that is coincident to the selected face.
Click OK to insert the interlocks.
Both the male and the female
interlocks are added to the
assembly.
Repeat for the other sides.
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9. Create ejector guide location sketch.
Create a sketch on the Front plane of the assembly.
Create sketch points and dimension as shown.
Exit the sketch .
Rename the sketch Ejector Guide Location.
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128
10. Create Support Pillar Location sketch.
Create the sketch on the Front plane of the assembly.
Create sketch points and dimension as shown.
Exit the sketch .
Rename the sketch Support Pillar Location.
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11. Add Ejector Guides
Start Components Gallery .
Select the component as shown:
Under Placement face, select the BCP plane under the move_half
subassembly.
Click to select Flip Direction.
Activate Select Sketch and
select the Ejector Guide Location
sketch.
Click OK to insert the
ejector guide.
The ejector guides are added to
the assembly.
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130
12. Add Ejector Bushings
Select the component as shown:
Under Placement face, select the ER1 plane under the move_half
subassembly.
Click to select Flip Direction.
Activate Select Sketch and select
the Ejector Guide Location sketch
Click OK to insert the ejector
bushings.
The ejector bushings are added to
the assembly.
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13. Add Support Pillars
Select the component as shown:
Under Placement face, select the SP plane under the move_half
subassembly as the placement face.
Click to select Flip Direction.
Activate Select Sketch and select the Support Pillar Location sketch
Click OK to insert the support pillar.
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132
Process: Main Insert Pocketing To pocket the main inserts, a sketch has to be present in the mold assembly. This
sketch has to be on a plane. The program will automatically calculate the depth of
the pocket required for the inserts.
Introducing:
Main Insert
Pocketing
The Core/Cavity Builder now incorporates a tool that easily
pockets the main insert from the moldbase plates.
Where To Find It: On the IMOLD toolbar, click Core/Cavity Builder ,
Create Insert Corner…
OR
From the SolidWorks menu, select IMOLD, Core/Cavity
Builder, Create Insert Corner…
14. Save the project
On the IMOLD toolbar, select Save , Save Project...
15. Main Insert Pocket
On IMOLD toolbar, select Core/Cavity Builder , Create Insert
Corner…
On the Insert Corner Creator dialog, uncheck the top Insert corner
parameters and check the below Pocket parameters group.
Select the pocket option types from the figure and the radius or
diameter of the pocket shapes.
In this exercise, select the radius corner option as displayed and
change the r to 8mm.
Click Execute to carry out the main insert pockets on the moldbase
plates.
Note: Pocketing main inserts can also be done through IMOLD Tools .
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Process: Adding Cooling Accessories IMOLD’s Cooling Accessories function can add cooling accessories like Plugs, nipples
etc, automatically to the cooling circuits. All you have to do is define which
components you would like to be added in.
Introducing:
Cooling Accessories
This function adds the components automatically to the
cooling circuits. You can add components to either selected
circuits or to all circuits at once.
Where To Find It: On the IMOLD toolbar, click Cooling Designer ,
Accessory.
-OR-
From the SolidWorks menu, select IMOLD, Cooling
Designer, Accessory …
Add cooling accessories.
On the IMOLD toolbar, click Cooling
Designer , Accessory...
Under Option, select All circuits.
Click Define button for Nipple.
Select the component as shown:
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134
Click Define button for Plug.
Select the component as shown:
Click Define button for ORing.
Select the component as shown:
When the accessories are defined, previews
of the components can be seen on the
graphics area.
Click OK to add the components.
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16. Add other components.
You can add other components as required using Components
Gallery , Add Component…
17. Fasten components.
Fasten the components using Iscrews .
18. Finished.
Save and close project.
136
Lesson 10 Finishing the Design
Upon successful completion of this lesson, you should be able to:
Purge moldbase.
Create configurations.
Pocketing.
Create drawings.
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Overview: Configurations can also be created for the core and cavity inserts. This can help us to
avoid having multiple parts in cases where the inserts differ only in minor details.
Drawings of the core and cavity views can be automatically created and a BOM
inserted to complete the design.
Highlights: Purge moldbase: We will purge the moldbase of all the unnecessary components.
We will also create the pockets for the moldbase components in the mold base.
Add Configurations: We will add configurations in order to create the cooling
channels to be different in the instances of the impression assembly.
Pocketing: We will create the pockets for all the standard components in the mold.
Creating Drawings: The core and cavity views of the mold assembly can be
automatically created and section lines can be drawn using a few clicks of the mouse.
A bill of materials can be generated using SolidWorks functions.
Process: Purge When the mold base is added in, all the plates are present in the moldbase assembly.
The plates that are not required for the current moldbase are suppressed. This
makes adding of new plates and changing the sizes a very simple operation.
At the end of the design, when the mold base design is finalized, these plates and
components are not required and may be purged. This will reduce the size of the
assembly.
1. Purge unwanted plates and components.
Select Moldbase Designer , Utilities, Purge...
Click Yes in the warning dialog box to confirm purging all the
unnecessary files.
All the unwanted plates and components are deleted from the
assembly and the working directory.
Introducing:
Purge
The Purge option will simplify the moldbase assembly. When
the user is satisfied with the moldbase and the design is finalized
the Purge button may be selected and the suppressed moldbase
plates will be deleted.
Where To Find
It: On the IMOLD toolbar, select Moldbase Designer ,
Utilities, Purge...
OR
From the SolidWorks menu, select IMOLD, Moldbase
Designer, Utilities, Purge…
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138
Process: Create Configurations Configurations allow similar parts to be created as a single model, thus making part
management much easier. In the context of mold design, configurations can be used
to advantage when creating similar inserts that differ in minor details such as runner
and gate sizes or position and size of cooling channels.
IMOLD offers tools to automate the creation of configurations for the impression
assembly and the core and cavity inserts.
Introducing:
Add Configuration
Delete
Configuration
Add Configuration will create configurations for the impression
assembly and the core and cavity inserts based on the number
of cavities in the layout.
Delete Configuration will delete all the configurations created
by IMOLD and replace them with a Default configuration.
Where To Find It: On the IMOLD toolbar, select IMOLD Tools ,
Configurations, Add or Delete.
From the SolidWorks menu, select IMOLD, IMOLD Tools,
Configurations, Add or Delete.
In this example, to illustrate how configurations can be used, we will create
configurations so that we can make the runner in one impression larger than the
other.
2. Create Configurations.
Select IMOLD Tools ,
Configuration, Add
Configuration… or Delete
Configuration...
Click Yes in the warning dialog
box to confirm creation of
configuration. Configurations
are created.
Notice that the impression
assembly will have two
configurations- Config1 and
Config2. The core and cavity
parts under Config1 will also
be configured as Config1 and
those under Config2 will be
configured as Config2.
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Process: Create Pockets Pocketing is the last operation to be performed in the mold design. This will enhance
performance and allow the unnecessary details to be supressed.
IMOLD’s Pocketing Manager allows unattended pocketing, so this operation can be
performed without the user being present.
3. Create pockets.
On the IMOLD toolbar, click IMOLD Tools
, Pocket Manager, Automatic…
Select the options as shown:
Click OK to create the pockets.
Note: The Forced pocketing option is used
if you wish to proceed with the pocketing
selection even pocketing may have been
done previously.
Note: Some mating relationships may be lost during pocketing. A
good understanding of SolidWorks assembly will come in handy.
Process: Create Drawings The modelling of the mold is complete. We will now create the layout drawings for
the mold using IMOLD Drawing and Sectioning.
Introducing:
IMOLD Drawing
IMOLD Drawing helps create automatic core and cavity
views of a mold design in 2D. IMOLD automatically place
the components in either the fixed half view or the moving
half view. You can choose to edit the component lists to
move parts from one view to another.
Where To Find It Click IMOLD Drawing , Core/Cavity View… on the
IMOLD toolbar
OR
From the SolidWorks menu, select IMOLD, IMOLD
Drawing, Core/Cavity View…
4. Start IMOLD Drawing.
On the IMOLD toolbar, click IMOLD Drawing and select
Core/Cavity view…
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5. Select the drawing sheet size and scale.
Under Drawing settings, select a Paper
Size of A0 and auto Scale.
From the drawing settings, you can choose
the paper size or browse from your own
template. Auto scaling will scale the
drawings proportionate to your paper size.
You can also choose the type of projection.
6. Entities Setting.
Expand Entities Setting group
. Here you can
choose to automatically populate drawing
entities like sectioning, dimensioning,
ballooning and bill of materials. By default,
all the options are checked.
7. Check components shown in the two
views.
Click on an entry to highlight it in the
graphics area.
To remove a component from the view,
select the component in the list and click
Clear.
To move a component between the views,
select the component and click
or .
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8. Move undetermined components.
Click to select Fixed Half.
Click Move to move the parts to the
Fixed half view.
9. Create Drawing.
Click OK .
A new drawing is created and the views
are placed automatically.
Save the drawing.
10. Edit Drawing Views.
You can change the drawing views to
emphasize components in the
assembly. Click View Manager ,
Show/Hide…
On the dialog, select the 3D view,
and choose By components the
options to show.
On the Component Category list,
check the components to show and uncheck the components to hide.
Click Apply to update the drawing.
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Introducing:
IMOLD Sectioning
IMOLD Sectioning will help you to create the section line on
an IMOLD Drawing by selecting the points the section line
has to pass through. Various selection filters are provided to
make the selection of the points easier. This function can
only be used on a drawing created with IMOLD Drawing.
Where To Find It Click IMOLD Drawing on the IMOLD toolbar
OR
From the SolidWorks menu, select IMOLD, IMOLD
Drawing.
In the above example, we automatically generated the sections views. Here, we can
delete the generated section views and create new section views.
11. Create section.
On the IMOLD toolbar, click IMOLD Drawing , Sectioning… and
the IMOLD Sectioning dialog appears.
12. Select the parent view.
Select the moving half view.
Select the direction.
Select the X axis.
Select screen point as the section position option then on the move
half drawing, zoom in and select points for sectioning. IMOLD will
automatically update and section through points selected. After
selecting the points, click OK to generate the section view.
Introducing:
Part Drawings
IMOLD can create individual drawings of all the parts in the
mold assembly. You can choose to create drawings for
selected parts or for all the parts in the mold.
Where To Find It? On the IMOLD toolbar, select IMOLD Drawing , Part
Drawings…
OR
From the SolidWorks menu, select IMOLD, IMOLD
Drawing, Part Drawings…
13. Create part drawings.
On the IMOLD toolbar, select IMOLD
Drawing , Part Drawings, Create
drawings...
Select the assembly Components that
you wish to create drawings for and the
Angle of Projection followed by the
View Number.
By checking the Export to a file option,
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Drawings will be created on a single file, separated by drawing sheets
instead of separate drawing files for each drawing.
Click OK to create the drawings.
Note: You can create Hole Charts on the generated part drawings by selecting
IMOLD Drawing , Part Drawings, Hole Chart…
14. Create a Bill of Materials.
On the IMOLD toolbar, select IMOLD Tools ,
BOM, Generate BOM…
In the Bill of Material window, select Export, To
Excel.
In Save as window, click Save to save the BOM to an Excel file with
the same name as the project.
Select Close to close the BOM window.
15. Insert BOM in the drawing,
Make the drawing of the mold the active document.
From the SolidWorks menu, select Insert, Object.
Select Create from file option.
Click Browse and select the Excel file created in
Step Error! Reference source not found..
Click to select Link.
Click OK to insert the BOM in the drawing.
16. Add dimensions and balloons.
You can add dimensions and balloons using SolidWorks functions if
necessary.
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17. Finished.
Save and close all files.