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Mold Design using Creo Parametric 3.0

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TRN-4517-M01-EN-LM-P01 01/16/2015 Initial Printing of:Mold Design using Creo Parametric 3.0

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Training Agenda

Day 1

Module 01 Introduction to the Creo Parametric Basic Mold ProcessModule 02 Design Model PreparationModule 03 Design Model AnalysisModule 04 Mold ModelsModule 05 ShrinkageModule 06 WorkpiecesModule 07 Mold Volume Creation

Day 2

Module 08 Parting LinesModule 09 Skirt SurfacesModule 10 Parting Surface CreationModule 11 Splitting Mold VolumesModule 12 Mold Component ExtractionModule 13 Mold Features CreationModule 14 Filling and Opening the Mold

Table of Contents

Mold Design using Creo Parametric 3.0Introduction to the Creo Parametric Basic Mold Process..................1-1

Creo Parametric Basic Mold Process ..........................................1-2Design Model Preparation ............................................................2-1

Understanding Mold Theory ......................................................2-2Preparing Design Models for the Mold Process .............................2-4Creating Profile Rib Features.....................................................2-6Creating Drafts Split at Sketch ...................................................2-9Creating Drafts Split at Curve .................................................. 2-12Creating Drafts Split at Surface ................................................ 2-15

Design Model Analysis.................................................................3-1Analyzing Design Models Theory................................................3-2Performing a Draft Check..........................................................3-3Performing a Section Thickness Check........................................3-7Performing a Thickness Check................................................. 3-12

Mold Models ...............................................................................4-1Creating New Mold Models .......................................................4-2Analyzing Model Accuracy ........................................................4-7Locating the Reference Model ................................................. 4-12Assembling the Reference Model ............................................. 4-17Creating the Reference Model ................................................. 4-21Redefining the Reference Model .............................................. 4-26Analyzing Reference Model Orientation ..................................... 4-28Analyzing Mold Cavity Layout .................................................. 4-34Analyzing Variable Mold Cavity Layout....................................... 4-38Analyzing Mold Cavity Layout Orientation................................... 4-42Calculating Projected Area ...................................................... 4-46

Shrinkage ...................................................................................5-1Understanding Shrinkage..........................................................5-2Applying Shrinkage by Scale .....................................................5-4Applying Shrinkage by Dimension...............................................5-8

Workpieces.................................................................................6-1Creating Display Styles ............................................................6-2Creating a Workpiece Automatically ............................................6-7Creating a Custom Automatic Workpiece ................................... 6-11Creating and Assembling a Workpiece Manually.......................... 6-13Reclassifying and Removing Mold Model Components ................. 6-18

Mold Volume Creation ..................................................................7-1

Surfacing Terms......................................................................7-2Understanding Mold Volumes ....................................................7-4Sketching Mold Volumes...........................................................7-6Creating Sliders using Boundary Quilts ...................................... 7-10Sketching Slider Mold Volumes ................................................ 7-15Creating a Reference Part Cutout ............................................. 7-21Sketching Lifter Mold Volumes ................................................. 7-26Replacing Surfaces and Trimming to Geometry ........................... 7-30Sketching Insert Mold Volumes ................................................ 7-35

Parting Lines ..............................................................................8-1Understanding Parting Lines......................................................8-2Creating an Automatic Parting Line Using Silhouette Curves ............8-3Analyzing Silhouette Curve Options: Slides ..................................8-8Analyzing Silhouette Curve Options: Loop Selection..................... 8-11

Skirt Surfaces .............................................................................9-1Understanding Parting Surfaces .................................................9-2Creating a Skirt Surface............................................................9-3Analyzing Skirt Surface Options: Extend Curves............................9-8Analyzing Skirt Surface Options: Tangent Conditions.................... 9-12Analyzing Skirt Surface Options: Extension Directions .................. 9-17Analyzing Skirt Surface Options: ShutOff Extension ..................... 9-22

Parting Surface Creation ............................................................ 10-1Analyzing Surface Editing and Manipulation Tools........................ 10-2Merging Surfaces .................................................................. 10-7Creating a Shadow Surface................................................... 10-11Creating a Parting Surface Manually ....................................... 10-16Creating Saddle Shutoff Surfaces ........................................... 10-17Creating Fill Surfaces........................................................... 10-22Extending Curves................................................................ 10-26Filling Loops....................................................................... 10-32Creating Shut Offs ............................................................... 10-36

Splitting Mold Volumes............................................................... 11-1Splitting the Workpiece ........................................................... 11-2Splitting Mold Volumes ........................................................... 11-6Splitting Volumes using Multiple Parting Surfaces .......................11-11Blanking and Unblanking Mold Items....................................... 11-15Analyzing Split Classification ................................................. 11-19

Mold Component Extraction ....................................................... 12-1Extracting Mold Components from Volumes................................ 12-2Applying Start Models to Mold Components................................ 12-6

Mold Features Creation .............................................................. 13-1

Creating Waterline Circuits ...................................................... 13-2Analyzing Waterline End Conditions .......................................... 13-6Performing a Waterlines Check .............................................. 13-10Understanding Mold Analysis Settings ..................................... 13-15Creating Sprues and Runners................................................ 13-17Creating Ejector Pin Clearance Holes...................................... 13-23Creating UDFs.................................................................... 13-29Placing UDFs ..................................................................... 13-34

Filling and Opening the Mold ...................................................... 14-1Creating a Molding ................................................................ 14-2Opening the Mold.................................................................. 14-4Draft Checking a Mold Opening Step......................................... 14-9Interference Checking a Mold Opening Step ............................. 14-12Viewing Mold Information ...................................................... 14-15

Student Preface Using the Header

In this topic, you learn about the course handbook layout andthe header used to begin each lab in Creo Parametric.

Course Handbook Layout:

Modules Topics

Concept Theory Procedure Exercise (if applicable)

Procedure / Exercise Header:

Course Handbook Layout

The information in this course handbook is organized to help students locateinformation after the course is complete. Each course is organized intomodules, each covering a general subject. Each module contains topics,with each topic focused on a specific portion of the module subject. Eachindividual topic in the module is divided into the following sections:

Concept This section contains the initial introduction to the topic andis presented during the class lecture as an overhead slide, typically withfigures and bullets.

Theory This section provides detailed information about contentintroduced in the Concept, and is discussed in the class lecture but notshown on the overhead slide. The Theory section contains additionalparagraphs of text, bullets, tables, and/or figures.

Procedure This section provides step-by-step instructions about how tocomplete the topic within Creo Parametric. Procedures are short, focused,and cover a specific topic. Procedures are found in the Student Handbookonly. Not every topic has a Procedure, as there are knowledge topics thatcontain only Concept and Theory.

Exercise Exercises are similar to procedures, except that they aretypically longer, more involved, and use more complicated models.Exercises also may cover multiple topics, so not every topic will have anassociated exercise. Exercises are found in the separate Exercise Guideand/or the online exercise HTML files.

The first module for certain courses is known as a processmodule. Process modules introduce you to the generic high-levelprocesses that will be taught over the span of the entire course.

Procedure / Exercise HeaderTo make the exercises and procedures (referred to collectively as labs) asconcise as possible, each begins with a header. The header lists the nameof the lab, the working directory, and the file you are to open.

The following items are indicated in the figure above, where applicable:

1. Procedure/Exercise Name This is the name of the lab.2. Scenario This briefly describes what will be done in the lab. The

Scenario is only found in Exercises.3. Close Windows/Erase Not Displayed A reminder that you should

close any open files and erase them from memory:

Click Close until the icon is no longer displayed.

Click Erase Not Displayed and then click OK.4. Folder Name This is the working directory for the lab. Lab files are

stored in topic folders within specific functional area folders. The path tothe lab files is: PTCU\CreoParametric3\functional_area_folder\topic_folderIn the example, Round is the functional area folder and Variableis the topic folder, so you would set the Working Directory toPTCU\CreoParametric3\Round\Variable. To set the working directory, right-click the folder in the folder tree orbrowser, and select Set Working Directory.

5. Model to Open This is the file to be opened from the workingdirectory. In the above example, VARIABLE_RAD.PRT is the model toopen. The model could be a part, drawing, assembly, and so on. Ifyou are expected to begin the lab without an open model, and insteadcreate a new model, you will see Create New.

To open the indicated model, right-click the file in the browser andselect Open.

6. Task Name Labs are broken into distinct tasks. There may be oneor more tasks within a lab.

7. Lab Steps These are the individual steps required to completea task.

Two other items to note for labs:

Saving Saving your work after completing a lab is optional, unlessotherwise stated.

Exercises Exercises follow the same header format as Procedures.

Setting Up Creo Parametric for Use with Training LabsBefore you begin a lab from any training course, it is important that youconfigure Creo Parametric to ensure the system is set up to run the labexercises properly. Therefore, if you are running the training labs on acomputer outside of a training center, follow these three basic steps:

Extract the class files zip file to a root level drive such as C: or D:. The extracted zip will create the default folder path automatically, such

as C:\PTCU\CreoParametric3\. Locate your existing Creo Parametric shortcut. Copy and paste the shortcut to your desktop. Right-click the newly pasted shortcut and select Properties. Select the Shortcut tab and set the Start In location to be the same as

the default folder. For example, C:\PTCU\CreoParametric3\. Start Creo Parametric using the newly configured shortcut. The default working directory will be set to the CreoParametric3 folder.

You can then navigate easily to the functional area and topic folders.

PROCEDURE - Student Preface Using the Header

In this exercise, you learn how to use the header to set up the CreoParametric working environment for each lab in the course.

Close Window Erase Not Displayed

SampleFunctionalArea\Topic1_Folder EXTRUDE_1.PRT

Step 1: Configure Creo Parametric to ensure the system is set up to runthe lab exercises properly.

Perform this task only if you are running the labs on a computeroutside of a training center, otherwise proceed to Task 2.

1. Extract the zipped class files to a root level drive such as C: or D:. The extracted ZIP will create the default folder path automatically,such as C:\PTCU\CreoParametric3.

2. Locate your existing Creo Parametric shortcut. Copy and paste the shortcut to your desktop. Right-click the newly pasted shortcut and select Properties. Select the Shortcut tab and set the Start In location to bePTCU\CreoParametric3.

3. Start Creo Parametric using the newly configured shortcut. The default working directory is set to the CreoParametric3 folder.You can then navigate easily to the functional area and topic folders.

Step 2: Close all open windows and erase all objects from memory toavoid any possible conflicts.

1. If you currently have files open, click Close from the Quick Accesstoolbar, until the icon no longer displays.

2. Click Erase Not Displayed from the Data group in the ribbon. Click OK if the Erase Not Displayed dialog box appears.

Step 3: Browse to and expand the functional area folder for this procedureand set the folder indicated in the header as the Creo Parametricworking directory.

1. Notice theSampleFunctionalArea\Topic1_Folder as indicated in the headerabove.

2. If necessary, select the FolderBrowser tab from thenavigator.

3. Click Working Directoryto view the current workingdirectory folder in the browser. Double-clickSampleFunctionalArea.

4. Right-click the Topic1_Folder folder and select Set WorkingDirectory.

5. ClickWorking Directory from the Common Folders section to displaythe contents of the new working directory in the browser.

Alternatively you can use the cascading folder path in thebrowser to navigate to the topic folder, and then right-click andselect Set Working Directory from the browser.

Step 4: Open the file for this procedure.

1. Notice the lab model EXTRUDE_1.PRT is specified in the headerabove. Double-click extrude_1.prt in the browser to open it.

2. You are now ready to begin the first task in the lab: Read the first task. Perform the first step, which in most cases will be to set the initialdatum display for the procedure or exercise.

Perform the remaining steps in the procedure or exercise.

Step 5: Set the initial datum display options.

1. The instruction for setting the datum display indicates which DatumDisplay types to enable and disable. For example, Enable only thefollowing Datum Display types: .

2. To set the datum display, first click the Datum Display drop-downmenu from the In Graphics toolbar.

3. Next, enable and disable thecheck boxes as necessary. Forexample you could disable theSelect All check box, and thenenable only the desired datumtypes.

4. The model should now appearas shown.

This completes the procedure.

Module1Introduction to the Creo Parametric BasicMold Process

Module OverviewIn this module, you learn about the basic mold process that is typically usedto take a part from its design stage to the creation of its mold. This simplifiedprocess is used at most companies; however, your specific company processmay differ. The process is explained in further detail throughout the coursemodules.

ObjectivesAfter completing this module, you will be able to: Run a draft check on a design model. Create a new mold model and assemble the reference model andworkpiece.

Create a slider mold volume for undercut geometry. Create the mold parting surface using a skirt surface. Create the mold components by splitting the mold volumes and generatingthe cavity components.

Create mold features by creating a runner in the mold model. Fill and open the mold by creating a molding and performing a moldopening analysis.

2015 PTC Module 1 | Page 1

Creo Parametric Basic Mold Process

The basic mold process can be summarized in seven high-levelsteps:

1. Preparing and AnalyzingDesign Models Drafts and draft/thicknesschecks.

2. Creating the Mold Model Reference model, shrinkage,and workpiece.

3. Creating Mold Volumes Sliders and other sketchedvolumes.

4. Creating Parting Surfaces5. Creating Mold Components

Split Mold Volumes andcreate cavity insert parts.

6. Creating Mold Features Waterlines, runners, andejector pin holes.

7. Filling and Opening the Mold Create a molding and openthe mold.

Figure 1 Analyzing aDesign Model

Figure 2 Creating the MoldModel and Parting Surface

Figure 3 Filling and Openingthe Mold

Preparing and Analyzing Design ModelsWhen you create a mold for a design model, you should first inspect themodel and analyze it to verify that it is indeed ready to be molded. Typically,the reference model geometry that you use for a mold model is derived fromthe design model. You can analyze the design model and reference modelfor adequate draft features and consistent thickness, adding draft features ifnecessary. It is critical that the final reference model has sufficient draft sothat it can be cleanly ejected from the mold.

Creating the Mold ModelStart the mold design by creating a mold manufacturing model. CreoParametric automatically creates the mold assembly when you create themold manufacturing model. The mold manufacturing model is also referred toas the Mold Model. Next, you assemble the reference model, which can beeither the design model that is to be molded or a new model derived fromthe design model. You can account for the contraction of the molding partduring cooling in the molding process by applying a shrinkage factor to thereference model. You also create or assemble the workpiece that represents

Module 1 | Page 2 2015 PTC

the full volume of all the mold components that are needed to complete themold model.

Creating Mold VolumesYou can create mold volumes manually using sketch-based features. Amold volume is a three-dimensional, enclosed surface quilt with no massin the workpiece of a mold model. You can also manually create a specialtype of mold volume called a slider. Creo Parametric can also create oneautomatically by calculating undercut areas in the mold model.

Creating Parting SurfacesYou can create parting surfaces for the mold model using the skirt surfacetechnique. The skirt surface technique requires parting lines that you createby using silhouette curves. You can use the parting surfaces to split theworkpiece into separate mold volumes later in the mold design process. Youcan also create parting surfaces manually.

Creating Mold ComponentsYou can split the workpiece volume into one or more mold volumes basedon the parting surfaces. The main mold volumes are classified into coreand cavity. Once the desired mold volumes are created and split, you cancreate the mold components, including sliders, from the mold volumes. Themold components are fully functional parts that you can open and modify inthe Part mode of Creo Parametric. You can also machine the componentsusing Creo NC.

Creating Mold FeaturesYou can create regular and user-defined assembly features to facilitate themolding process. Regular features include mold-specific features such aswaterlines, runners, and ejector-pin clearance holes. You can also createuser-defined features from regular cuts and slots that are placed on moldmodels to create sprues.

Filling and Opening the MoldYou can create the molding component that represents the filled mold cavity.Creo Parametric creates the molding component automatically by determiningthe volume remaining in the workpiece after extracting the mold components.

You can then define the steps for the mold-opening process for everycomponent in the mold model except the reference model and workpiece.During the mold opening analysis, you can determine whether there isinterference with any static components for each of the steps that you define.


PROCEDURE - Creo Parametric Basic Mold Process

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

Prepare and analyze a design model for manufacturing. Create a mold model. Create mold volumes. Create a parting surface. Create mold components. Create mold features. Fill and open the resulting mold.

You are a design engineer in a camera company. You have been providedwith the front housing of a new camera design and are tasked with creatingthe manufacturing mold for it. You know from previously received modelsthat you must first prepare and analyze the design model to verify that itcan be manufactured.

Once you have verified that the design model can be manufactured usinga mold, you can create the mold model and mold volumes. You can thencreate the mold-parting surface and mold components. Finally, you can filland open the resulting mold.


Process\Mold CAMERA.PRT

Step 1: Prepare and analyze a design model for manufacturing.

1. Enable only the following DatumDisplay types: .

2. In the ribbon, select theApplications tab.

3. Click Mold/Cast from theEngineering group to toggle fromthe standard application to theMold application.

4. Click Draft from the Analysisgroup.


5. To perform a draft check, do thefollowing: In the model tree, selectCAMERA.PRT.

In the Draft Analysis dialogbox, clear the Use the pulldirection check box.

Click in the Direction collectorand select datum plane TOP.

Type 0.5 as the value for theDraft angle and press ENTER.

6. In the Color Scale dialog box,click Expand .

7. Edit the number of colors to 3.

The positive draft areasappear in blue and thenegative draft areas in red.The vertical walls appearin gray. This demonstratesthat the part is fully draftedand is ready to be used increating a mold model.

8. Click OK from the Draft Analysis dialog box.

9. Click Close from the Quick Access toolbar.


Step 2: Create the camera mold model.

1. Click New from the QuickAccess toolbar.

2. In the New dialog box, do thefollowing: Select Manufacturing as theType.

Select Mold cavity as theSub-type.

Type camera_mold as theName.

Clear the Use defaulttemplate check box andclick OK.

Select the mmns_mfg_moldtemplate.

Click OK.

3. Click File > Options and select the Configuration Editor category. Click Add. Type enable_absolute_accuracy in the Option name field. Select yes as the Option value and click OK > OK > No.

4. Select Locate Reference Modelfrom the Reference Model

types drop-down menu in theReference Model & Workpiecegroup to assemble the referencemodel.

5. In the Open dialog box, selectCAMERA.PRT and click Open.

6. In the Create Reference Modeldialog box, select Same modelas the Reference model typeand click OK.

7. Specify the mold cavity layout bydoing the following: Click Reference Model Origin

from the Layout dialogbox and select the MAINcoordinate system in theCAMERA.PRT sub-window.

Click Preview and noticehow the reference model isassembled and oriented.


8. In the Layout dialog box, selectRectangular as the Layout. Select X-Symmetric as theOrientation.

Type 120 as the X Incrementvalue and 150 as the YIncrement value.

Click Preview. Notice that a pattern ofreference models, symmetricabout the X-axis, areassembled to create amulti-cavity mold.

9. In the Layout dialog box, selectY-Symmetric as the Orientationand click Preview.

10. Notice that a pattern of referencemodels, symmetric about theY-axis, are assembled to createa multi-cavity mold.

11. Select Single as the Layout tocreate a single-cavity mold andclick OK.

12. In the Warning message window,click OK to accept the change inthe absolute accuracy value.

13. Apply shrinkage to the referencemodel by doing the following:

Select Shrink by scalefrom the Shrinkage typesdrop-down menu in theModifiers group.

In the model tree, click thenode for CAMERA.PRT toexpand it and select thePRT_CSYS_DEF coordinatesystem.

Type 0.005 as the Shrink Ratioin the Shrinkage By Scaledialog box and press ENTER.

Click Apply Changes .


14. Select Automatic Workpiecefrom the Workpiece

types drop-down menu in theReference Model & Workpiecegroup to create an automaticworkpiece.

15. In the Automatic Workpiecedialog box, do the following: Select the MOLD_DEF_CSYScoordinate system from thegraphics window as the MoldOrigin.

Type 20 for the negative, andtype 20 for the positive Xdirection values.

Type 30 for the negative, andtype 30 for the positive Ydirection values.

Type 20 for the negative, andtype 20 for the positive Zdirection values.

Click OK.

16. Disable Plane Display andCsys Display .

17. Select CAMERA_MOLD_WRK.PRT.

18. In the ribbon, select the Viewtab.

19. Click the Model Display groupdrop-down menu and selectComponent Display Style >Wireframe.

20. Select the Mold tab.


Step 3: Create slider mold volumes.

1. Select Mold Volume from the Mold Volume types drop-downmenu in the Parting Surface & Mold Volume group to create the slidervolume.

2. To rename the mold volume feature, do the following:

Click Properties from the Controls group. Type Slider as the Name of the mold volume in the Propertiesdialog box and press ENTER.

3. Click Slider from the Volume Tools group.

4. In the Slider Volume dialog box,do the following: Click Calculate UndercutBoundaries .

Press CTRL and select Quilt1 and Quilt 2 from the Excludecolumn.

Click Include BoundarySurfaces to add theselected quilts to the Includecolumn for slider calculation.

Click Select Projection Planeand select the right surface

of the workpiece.

5. Click Apply Changes fromthe Slider Volume dialog box.

6. Click OK from the Controlsgroup.

You can also manuallysketch the shape of theslider volume to represent astandard shape that can bemanufactured.


Step 4: Create a parting surface.

1. Click Silhouette Curve fromthe Design Features group toautomatically create parting linecurves.

2. In the Silhouette Curve dialogbox, click Preview to observe thesilhouette curves automaticallycreated at all edges of the moldmodel.

3. Notice that some adjustmentsneed to be made to the automaticparting line curves.

4. In the Silhouette Curve dialogbox, double-click Slides. Select the slider volume fromthe graphics window.

Click Done/Return from themenu manager.

5. In the Silhouette Curvedialog box, double-click LoopSelection. Select the Chains tab. Select chain 41 and clickLower to move the curve fromthe upper edge to the loweredge of the hole.

Click OK from the LoopSelection dialog box.

6. Click OK from the SilhouetteCurve dialog box to complete theparting line.


7. Click Parting Surface fromthe Parting Surface & MoldVolume group.

8. Click Skirt Surface from theSurfacing group to create anautomatic parting surface.

9. Select the workpiece.

10. Select the silhouette curve.

11. Click Done from the menumanager.

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

13. In the Extension Control dialogbox, select the ExtensionDirections tab. Click Add. Press CTRL and select thetwo vertices.

14. Click OK from the Select dialogbox.


16. Query-select the left surface ofthe workpiece as the normalplane.

17. Click Okay from the menumanager.

18. Click OK to close the ExtensionControl dialog box.

19. Click OK from the Skirt Surfacedialog box.

20. Click OK from the Controlsgroup to complete the partingsurface.


Step 5: Create the mold components.

1. Select Volume Split from theMold Volume types drop-downmenu in the Parting Surface &Mold Volume group to split theworkpiece into mold volumes.

2. Click Two Volumes > AllWrkpcs > Done from the menumanager.

3. Select the slider and click OKfrom the Select dialog box.

4. Click OK from the Split dialogbox.

5. In the Properties dialog box, type main_vol as the Name of the firstvolume and press ENTER.

6. In the Properties dialog box, type slider_vol as the Name of thesecond volume and press ENTER.

7. Click Volume Split to splitthe main volume into core andcavity inserts.

8. Click Two Volumes > MoldVolume > Done .

9. In the Search Tool dialog box, dothe following: Select Quilt: F11(MAIN_VOL)from the list of items found.

Click Add Item to addthe selected quilt to the list ofitems selected.

Click Close.

10. Select the parting surface (youmay have to use query select)and click OK from the Selectdialog box.

11. Click OK from the Split dialogbox.

12. In the Properties dialog box, type core as the Name of the first volume(the lower half) and press ENTER.

13. In the Properties dialog box, type cavity as the Name of the secondvolume (the upper half) and press ENTER.


14. Select Cavity insertfrom the Mold Componenttypes drop-down menu in theComponents group.

15. In the Create Mold Componentdialog box, press CTRL andselect CAVITY, CORE, andSLIDER. Click OK.

16. Notice that the mold componentsappear as individual solid partsin the model tree.

17. In the model tree, right-clickCORE.PRT and select Open.

18. Click Close .

19. In the ribbon, select the View tab.

20. Click Mold Display from the Visibility group.

21. Select the Mold tab.

22. In the Blank and Unblank dialog box, press CTRL and selectCAMERA, CAMERA_MOLD_WRK, and CORE from the VisibleComponents list and click Blank.

Click Parting surface as the Filter. Select PART_SURF_1 and click Blank.

Click Volume as the Filter. Select SLIDER_VOL and click Blank. Click OK.

23. In the model tree, right-click SILH_CURVE_1 and select Hide .


Step 6: Create a runner mold feature.

1. Click Runner from theProduction Features group.

2. Click Half Round from the menumanager.

3. Type 3 as the runner diameterand press ENTER.

4. Query-select the bottom surfaceas the Sketching Plane and clickOkay > Default from the menumanager.

5. Click Sketch View from theIn Graphics toolbar.

6. Select datum planeMOLD_RIGHT and the topand bottom edges as references,and click Close from theReferences dialog box.

7. Click Line Chain and sketchtwo lines of equal length.

8. Click One-by-One and editthe length to 29.

9. Click OK .

10. Press CTRL+D and selectCAVITY.PRT as the intersectedcomponent.

11. Click OK from the IntersectedComponents dialog box.

12. Click OK from the Runner dialogbox.

13. In the model tree, right-clickCORE.PRT and select Unblank.


Step 7: Fill and open the mold.

1. Click Create Molding fromthe Components group to createthe molding.

2. Type camera_molding as thePart name and press ENTER.

3. Press ENTER to accept thedefault Mold Part CommonName.

4. Click Mold Opening fromthe Analysis group to perform amold-opening analysis.

5. Click Define Step > DefineMove from the menu manager.

6. Select SLIDER.PRT.

7. ClickOK in the Select dialog box.

8. Select the edge to define thedirection of the move.

9. Type -100 as the translationvalue and press ENTER.



12. Select CAVITY.PRT.




15. Type 100 as the translation valueand press ENTER.



18. Select CORE.PRT.



21. Type -100 as the translationvalue and press ENTER.


23. Click Done/Return from themenu manager.


24. Click in the background to de-select all items.

25. Click Regenerate from the Quick Access toolbar.

26. Click Save from the Quick Access toolbar and click OK to savethe model.

27. Click File > Manage Session > Erase Current, then click Select All, and click OK to erase the model from memory.



Module2Design Model Preparation

Module OverviewIt is not uncommon for designers to hand off design models without drafts orribs because they do not know enough about mold design in order to makedecisions about parting surfaces and pull direction, and they may not becomfortable with specifying draft angles or creating ribs. The reference modelgeometry for a mold model is derived from the corresponding design modelgeometry. Consequently, the mold designer may have to prepare the designmodel so that a mold can be created from it.

In this module, you learn the basics of mold design and how to prepare adesign model for the mold process.

ObjectivesAfter completing this module, you will be able to: Define the main components of a mold. Specify the names of the various paths used to flow material into the mold. Recall the items typically required of a design model to create a robustmold and part.

Create a robust mold model by creating profile rib features. Apply your knowledge of what makes a robust mold by defining draft andsplitting it using various techniques.


Understanding Mold Theory

The mold designer creates the mold and its components usingCreo Parametric's Mold mode.

A mold consists of a core andcavity.

Sprues and runners channelmaterial into the void.

Ejector pins eject the solidifiedpart.

Figure 1 Moldbase LayoutCreated in EMX

Figure 2 Mold Core and CavityFigure 3 Sprue and Runner

Design

Understanding Manufacturing Mold TheoryFrom a manufacturing point of view, in its simplest form, a mold consists ofa core and cavity which are split at a parting line. The core is the convexfeature side of the mold that enters an opposing cavity when the mold isclosed. The cavity is the concave feature side of the mold into which anopposing core enters when the mold is closed. An example of a mold coreand cavity is shown in Figure 2. The void between the closed core and cavityis filled with a material such as plastic. This material-filled void becomesthe resulting part when it solidifies.

For the material to find its way into the void, there must be various chambersand paths created in the mold. These chambers are defined as follows:

Sprues The route the plastic material takes from the point where it entersthe mold until it reaches the runners. When solidified, it remains attachedto the part via one or more runners and is typically removed in finishing.


Runners and gates Channels machined into the mold that direct theplastic material from the sprue into the mold cavity.

In Figure 3, you can see the sprue, runners, and gates attached to the fourmolded pucks.

Once the material solidifies, the part can be removed from the mold. To aid inejecting the part, mold components called ejector pins are often designed intothe mold. The sizes and arrangement of the pins are selected to minimize theimpact on the part design.

Understanding CAD Mold TheoryFrom a CAD point of view, a designer typically hands off a completed ornearly completed Creo Parametric design model to a mold designer. Themold designer then takes the design model and uses it to create a Referencemodel within Creo Parametric's Mold mode. The mold designer uses theReference model to create the resulting mold core and cavity componentswhich create the void of the Reference model. The mold core and cavitycomponents split at a location called the parting surface, which the molddesigner must determine.

Once the mold designer creates the mold components in Creo Parametric'sMold mode, he or she can use the Expert Moldbase Extension to createthe entire moldbase layout. The Expert Moldbase Extension, or EMX, usesa 2-D process-driven GUI to guide the mold designer toward the optimaldesign. It uses a catalog of standard components (DME, HASCO, FUTABA,PROGRESSIVE, STARK, and so on), or customized components. Figure 1shows a completed moldbase that was developed with the Expert MoldbaseExtension.

Mold Design using Creo Parametric focuses only on the creation of the moldcomponents and does not cover the Expert Moldbase Extension.


Preparing Design Models for the Mold Process

You may not be able to create a mold from a perfectly validdesign model.

Design model requirements formolding typically include: Draft on vertical surfaces. Uniform thickness. Ribs. Ejector pin pads.

Preparation guidelines: Draft applied to vertical faces. Ribs should be about half the

model thickness and draftedwhere needed.

Create ejector pin pads whereneeded.

Reorder or insert draft featuresbefore rounds if possible.

Figure 1 Original Design Model

Figure 2 Design ModelPrepared for Molding

Preparing Design Models for the Mold ProcessEven though the design model you receive may be a valid design model, youmay not be able to use the model to create a robust mold. The following itemsare typically required of the design model to create a robust mold and part:

Draft Facilitates the removal of the part from the mold. Uniform thickness Areas of a part that are thicker than others can resultin sink zones or warping when cooling occurs.

Ribs Add strength and rigidity to the molded part. Ejector pin pads Sufficient material is needed for the full diameter ofan ejector pin at the location where it pushes against the resulting part toeject it from the mold.

These items may not be present in the design model when you receive itbecause the design engineer does not know where the parting surface orejector pins will be located in the mold. Therefore, you must prepare thedesign model for the mold process by adding the necessary features neededto make a mold from the model.


Guidelines for Proper Design Model PreparationThe following guidelines indicate how to properly prepare a design modelfor molding.

Try to create models that are of uniform thickness to prevent sink zones orwarping in the resulting molded part.

Create ribs that are approximately half the model's wall thickness to preventsink. Apply draft to the rib walls if they are vertical faces. Vertical facesare those that are vertical with respect to how the mold opens. In Figure 2,two ribs have been created and draft has been applied.

Be aware of the need to accommodate ejector pins in your design model forproper ejection from the mold. Create ejector pin pads at these locationsin the model where the ejector pins push against the model to eject it. InFigure 2, four ejector pin pads have been created.

Apply draft in the proper direction at least 0.5 degrees on all verticalfaces. Draft has been applied to all faces that are vertical with respect tohow the mold opens.

When creating Draft features in Creo Parametric, either reorder them to becreated before any related rounds or insert them before the rounds. Thispractice results in a more robust Creo Parametric model. In Figure 2, thedraft has been inserted before the adjacent rounds.


Creating Profile Rib Features

A profile rib feature is similar to an extruded protrusion, exceptthat it requires an open section sketch.

Profile rib features require an opensketch.

You can edit the side that thickens. You can flip to which side of thesketch you want to create the rib.

Rib geometry adapts to theadjacent, solid geometry.

Figure 1 Viewing Open Sketches

Figure 2 Editing the Sidethat Thickens

Figure 3 Flipping Which Sidethe Rib is Created

Creating Profile Rib FeaturesRibs are typically used to strengthen parts. A profile rib feature is similar to anextruded protrusion, except that it requires an open section sketch. The ribalso conforms to existing planar or cylindrical geometry when it is extruded.After you select an open section sketch and set a thickness, Creo Parametricautomatically creates the profile rib feature by merging it with your model.The system can add material above or below the sketch, and the thicknesscan be applied on either side, or be symmetric about the sketch. The ProfileRib enables you to create rib features in less time than it would take foryou to create and sketch a protrusion.


PROCEDURE - Creating Profile Rib Features


Rib\Profile RIB.PRT

Task 1: Create profile rib features on a part model.

1. Disable all Datum Display types.

2. Select Profile Rib from theRib types drop-down menu in theEngineering group.

3. Select RIB_SKETCH-1.

4. Drag the handle and edit thewidth to 75.

5. Click Complete Featurefrom the dashboard.

Notice the angled rib surface is not planar; it is contoured tomatch the curved surface which is adjacent to the sketch.

6. Click Profile Rib .

7. Select RIB_SKETCH-2 .

8. Orient to the RIGHT vieworientation.

9. Drag the handle and edit thewidth to 25. The rib is centeredabout the sketch.

10. Click Change ThicknessOption from the dashboard.The rib moves to the left of thesketch.


11. Click Change ThicknessOption again. The rib movesto the right of the sketch.

12. Click Complete Feature .

13. Reorient the model.

14. Click Profile Rib .

15. Select RIB_SKETCH-3 . The ribis above the sketch.

16. Click the arrow in the graphicswindow. The rib is now on thebottom of the sketch.




Creating Drafts Split at Sketch

You can use a sketch to define custom split lines.

Sketch becomes linked. Sketch can be unlinked. A new sketch can be defined. Sketch need not lie on draft surface.

Figure 1 Viewing Sketch Figure 2 Draft Split at Sketch

Creating Drafts Split at SketchYou can specify a sketch to be used as the split object. This enables you tocreate custom split lines. When you select an existing sketch as the splitobject, it becomes linked. However, you can unlink the sketch if desired. Youcan also define a new sketch. If the sketch does not lie on the draft surface,Creo Parametric projects it onto the draft surface in the direction normal tothe sketching plane. The sketch in Figure 1 was used as the Split object forthe draft in Figure 2.


PROCEDURE - Creating Drafts Split at Sketch


Draft\Split-Sketch DRAFT_SPLIT-SKETCH.PRT

Task 1: Create a draft split at a sketch.

1. Disable all Datum display types.

2. Select Draft from the Drafttypes drop-down menu. Select the large, front surfacecontaining the sketch.

3. Right-click and select DraftHinges. Select the top surface of theleft rectangular step.

4. Drag the angle so the upper draftportion goes into the model.

5. In the dashboard, select theSplit tab. Select Split by split object asthe Split option.

Select sketch SPLIT_SKETCH.

Select Draft second sideonly as the Side option.

6. Drag the angle so the draft goesinto the model.

7. Click Preview Feature .

8. Click Resume Feature .

9. In the dashboard, select theSplit tab. Select Draft first side only asthe Side option.




12. In the dashboard, select theSplit tab. Select Draft sidesindependently as the Sideoption.

Edit both draft angles to 7 sothe draft goes into the model.




Creating Drafts Split at Curve

You can create a draft that splits at a waistline curve.

Material at the curve remains constant.

Figure 1 The Datum CurveFigure 2 Draft Split at

Datum Curve

Creating Drafts Split at CurveYou can create a draft that splits at a waistline curve. This causes thematerial at the curve to remain constant. The curve shown in Figure 1 wasused as the draft hinge. The draft was then split at this draft hinge to createthe resulting geometry in Figure 2.

If you specify a curve as the draft hinge, you must also specify a separatepull direction reference.


PROCEDURE - Creating Drafts Split at Curve


Draft\Split-Curve DRAFT_SPLIT-CURVE.PRT

Task 1: Create a draft split at a curve.


2. Select Draft from the Drafttypes drop-down list. Select the front surface.

3. Right-click and select DraftHinges. Select the curve.

4. Right-click and select PullDirection. Select datum plane TOP fromthe model tree.

5. Edit the draft angle to 10.

6. In the dashboard, click ReverseAngle .



9. In the dashboard, select theSplit tab. Select Split by draft hinge asthe Split option.

Select Draft sidesdependently as the Sideoption.

10. Click Reverse Angle .



12. Notice that this draft has removedmaterial from the top and bottomof the model.



Creating Drafts Split at Surface

You can create a draft that splits at a waistline surface, causingmaterial at the surface to be added.

Additional draft hinges can becreated. You must first split the draft

surfaces. Material remains the same size

at both draft hinge locations.

Figure 1 Draft Split at Surface

Figure 2 Splitting the Draftat Surface

Figure 3 Selecting MultipleDraft Hinges

Creating Drafts Split at SurfaceYou can create a draft that splits at a waistline surface, causing material atthe surface to be added, as shown in Figure 1. This type of draft enables youto select additional draft hinges. To select a second hinge, you must first splitthe draft surfaces. The model remains the same size at both draft hingelocations. In Figure 2, the selected surface is used as the split object. Oncethis split object was defined, a second draft hinge was able to be added,as shown in Figure 3.


PROCEDURE - Creating Drafts Split at Surface


Draft\Split-Surface DRAFT_SPLIT-SURFACE.PRT

Task 1: Create a draft split at a surface.


2. Select Draft from the Drafttypes drop-down list. Select the front surface.

3. Right-click and select DraftHinges. Select an edge on the front ofthe top surface.

Press SHIFT, cursor over anadjacent edge, right-click toquery, and select the upperTangent chain.

4. Right-click and select PullDirection. Select datum plane TOP fromthe model tree.

5. Edit the draft angle to 10.

6. In the dashboard, select theSplit tab. Select Split by split object asthe Split option.

Select the surface quilt.

7. Edit the lower draft angle to 10.

8. Click Reverse Angle for thelower draft angle.


9. In the dashboard, select theReferences tab.

10. Right-click and select DraftHinges. Press CTRL and select anedge on the front of the bottomsurface.

Press SHIFT, cursor over anadjacent edge, right-click toquery, and select the bottomTangent Chain.

The Draft hinges collectorshould contain two TangentChains.


12. In the model tree, right-clickQUILT and select Hide .

13. Note that this draft has addedmaterial to the center of themodel.



Module3Design Model Analysis

Module OverviewCreo Parametric enables you to analyze the design model for key elementssuch as proper draft and thickness before creating the mold model. Thesetools help you ensure that the design model is acceptable to begin moldcreation.

In this module, you perform draft and thickness checks on design models.

ObjectivesAfter completing this module, you will be able to: Understand the different types of analyses you can perform on a designmodel.

Perform a draft check on a design model. Perform a section thickness check on a design model. Perform a thickness check on a design model.


Analyzing Design Models Theory

Analysis tools enable you to ensure that the design model isacceptable for mold creation.

Analysis tools include: Draft check Section Thickness check Thickness check

Analysis tools can be used oncomponents other than the designmodel.

Analysis tools can be used attimes other than before the moldis created. Figure 1 Draft Check

Figure 2 Section Thickness Check

Analyzing Design Models TheoryYou can perform analyses on design models before creating the mold model.Analysis tools enable you to ensure that the design model is acceptable formold creation. You can perform the following types of analyses on designmodels:

Draft check Thickness check Section Thickness check

You usually use these analysis tools before the mold is created, but you canalso use them at almost any point during the mold process, including:

Parting line creation If the parting line location is modified slightly you canperform a draft check to verify that the model is still properly drafted.

Parting surface creation Again, if the parting surface is modified you canperform a draft check to verify that the model is still properly drafted.

Mold component creation You can perform a thickness check oncomponents other than the design model. You can perform a thicknesscheck on the core or cavity component to verify that it has sufficientthickness to handle the stress during the molding part creation.


Performing a Draft Check

You can perform a draft analysis to ultimately determine whethera model is suitable for a mold operation.

You do not need to be in Moldmode to perform the analysis.

Draft Check Specify references:

Surface Direction

Specify options: Draft angle Sample Quality

Plots: 3-Color Rainbow

Figure 1 Incorrectly Drafted Pegs

Figure 2 Peg Geometry Updatedfor Correct Draft Figure 3 Rainbow Plot

Performing a Draft CheckYou can use draft checking to determine whether the design model hasthe correct surfaces drafted and suitable draft angles to facilitate themold-opening process as well as the removal of the molding component. Toperform the draft check, click Draft from the Analysis group if in Moldmode, or click Draft from the Inspect Geometry group in the Analysis tabif in Part mode.

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

Surface Specifies the surfaces for which the draft analysis is to be run.You can select surfaces or quilts individually, or select the part node in themodel tree to select all solid geometry.

Direction Specifies the direction to be used for the draft analysis. Usually,the pull direction is the direction in which the mold opens. If in a moldmodel, the system automatically uses the pull direction by default, but youcan also specify your own direction reference.

You must also specify the following options:

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


Sample Enables you to specify how the plot resolution is calculated.Options include Quality, Number, and Step.

Quality Adjusts the quality of the plot.

When you perform a Draft analysis, the system produces a color plot of thedraft angles. Based on the coloring, you can identify areas that do not havesufficient draft angles, or incorrect direction draft angles. There are twodifferent types of color plots you can display:

3-Color Plot Displays a three color plot in the graphics window.Sufficient positive draft angles appear in blue, sufficient negative draftangles appear in red, and insufficient angles appear in white.

Rainbow Plot Displays the color scale as a rainbow plot.

You can specify the number of colors to display, and whether the color scaleis shown as continuous or non-continuous.


PROCEDURE - Performing a Draft Check


Analysis\Draft_Check DRAFT-CHECK.PRT

Task 1: Perform a draft check on a part model.


2. In the ribbon, select theApplications tab.

3. Click Mold/Cast from theEngineering group.

4. Click Draft from the Analysisgroup.

5. Select DRAFT-CHECK.PRTfrom the model tree.

6. In the Draft Analysis dialog box,clear the Use the pull directioncheck box.

7. Right-click in the graphicswindow and select DirectionCollector.

8. Select datum plane TOP fromthe model tree.

9. Edit the draft angle to 3 ifnecessary.

10. Rotate the model so that you canview the pegs underneath.

11. Notice that there is positive drafton the pegs and it needs to benegative.

12. In the Draft Analysis dialog box,click Flip.

13. Notice that the colors and anglevalues have reversed.

14. Click OK from the Draft Analysisdialog box.


15. In the model tree, right-clickDraft 3 and select Edit .

16. Edit the draft angle to -3 andclick twice in the background tofinish editing the model.

17. Click Draft .

18. Select DRAFT-CHECK.PRTfrom the model tree.

19. In the Draft Analysis dialog box,clear the Use the pull directioncheck box.

20. Right-click in the graphicswindow and select DirectionCollector.

21. Select datum plane TOP fromthe model tree.

22. Notice that the pegs are nowdrafted the correct way formolding.

23. In the Draft Analysis dialog box,edit the Draft angle to 4

24. In the Color Scale dialog box,click Expand . Edit the number of colors to 3.

25. Click Rainbow Plot .

26. Click 3-Color Plot .

27. Click OK from the Draft Analysis dialog box.



Performing a Section Thickness Check

You can perform a section thickness check on a part model tocheck for maximum or minimum thickness at specified locations. Two methods: Select one or more planes. Select references to create

incremental slices. Two checks available: Maximum thickness. Minimum thickness.

Interface is slightly different inpart model versus manufacturingmodel.

Figure 1 Displaying SectionThickness Cross-Sections Through

Selected Planes

Figure 2 Displaying SectionThickness Cross-Sections

Through Slices

Performing a Section Thickness Check on a ModelYou can perform a thickness check on a model by selecting the Analysis tabin the ribbon, and then clicking Section Thickness from the Model Reportgroup. You can measure thickness using either of the following methods:

Select one or more planes through which the thickness is measured. Youcan press CTRL to select multiple planar references.

Select references to create incremental cross-section slices through whichthickness is measured. To create these incremental slices, you mustspecify the following references: From slices This specifies the start point of slicing. You can select

either vertices or datum points for this reference. To slices This specifies the end point of slicing. Again, you can select

either vertices or datum points for this reference. Direction This specifies the direction of slicing. If necessary, you can

click the direction arrow in the graphics window to flip the direction ofslicing to point between the From Slices and To Slices references.

Once you have specified the correct slicing references, you can specifythe following options:


Use number of slices This specifies the number of slices to be createdbetween the selected references.

Offset The incremental offset value that separates each cross-sectionalslice.

The Slices reference collectors become grayed out if you select aPlane reference to perform the thickness check.

You can configure the system to perform the following two thickness checksat each specified reference:

Maximum Checks for maximum thickness. The system performs amaximum thickness check based on the value you have specified.

Minimum Checks for minimum thickness. The system performs aminimum thickness check based on the value you have specified.

The Thickness dialog box displays the results for each thicknesscross-section location. When you select a result in the dialog box, thethickness cross-section displays in the graphics window. The Thicknessdialog box also indicates whether the thickness at each cross-sectionsurpassed the minimum or maximum thicknesses specified.

Performing a Section Thickness Check in a Manufacturing ModelYou can also perform a section thickness check in the mold model by clickingSection Thickness from the Analysis group in the Mold tab. Because thesection thickness check occurs within the context of an assembly, you mustspecify the part that the thickness check is to be performed on.

Once the part is specified, the thickness check is similar to that of the modelanalysis thickness check, although the interface is slightly different. You caneither select one or more planes through which to measure the thickness, oryou can have the system create slices based on selected references. Thesystem can check for both maximum and minimum thickness based on thespecified thickness value you provide, and the results appear in the ModelAnalysis dialog box similar to those of the Thickness dialog box.


PROCEDURE - Performing a Section Thickness Check


Analysis\Section-Thickness_Check THICKNESS-CHECK.PRT

Task 1: Perform a thickness check on a part model.


2. In the ribbon, select the Analysistab.

3. Click the Model Report groupdrop-down menu and selectSection Thickness .

4. Press CTRL and select datumplanes FRONT, TOP, andRIGHT.

5. In the Thickness dialog box, editthe Maximum value to 0.2 andclick Preview. Notice that the #1 and #2results have an area ofthickness greater than 0.2.

Select the #2 result, and noticethat it highlights in the graphicswindow.

6. In the Thickness dialog box, clickShow All. Notice that all three resultshighlight in the graphicswindow.

Click Clear.


7. In the Thickness dialog box,right-click in the Planes collectorand select Remove All. Click in the From slicescollector and select datumpoint PNT0.

Select datum point PNT1 asthe To slices reference.

Select datum plane RIGHT forthe Direction collector.

Edit the Offset to 2. Clear the Maximum checkbox.

Select the Minimum checkbox and edit the value to 0.15.

Click Preview.

8. Click Show All.

9. Click OK from the Thicknessdialog box.

Task 2: Perform a thickness check in a mold cavity.

1. Click Open from the Quick Access toolbar and double-clickMFG_THICKNESS.ASM.

2. Click the Analysis group drop-down menu and select SectionThickness .

3. Select the model from the graphics window.


4. In the Model Analysis dialogbox, click Slices for the SetupThickness Check. Select datum point PNT2 asthe Start Point.

Select datum point PNT3 asthe End Point.

Select datum planeMAIN_PARTING_PLN asthe Slice Direction.

Click Okay from the menumanager to accept the upwarddirection.

Select the Use number ofslices check box and edit thevalue to 6 slices.

Edit the Slice Offset to 1. Clear the Max check box andselect the Min check box,editing its value to 0.3.

Click Compute. Click Close.



Performing a Thickness Check

You can perform a 3-D thickness check on a part model to checkfor maximum or minimum thickness violations. Measure: All solid geometry. Individually selected surfaces.

Two thickness checks available: Maximum thickness Minimum thickness

You can specify: Minimum/Maximum thickness

values. Minimum/Maximum thickness

color. Neutral color. Post processing.

Figure 1 Viewing Min and MaxThickness Violations

Figure 2 Viewing Post ProcessedMin and Max Thickness Violations

Performing a Thickness CheckYou can perform a 3-D thickness check on a part model to check formaximum or minimum thickness violations. The thickness check reduces thetime to analyze wall thickness of complicated parts.

The Thickness option is available in multiple places in the CreoParametric user interface:

In Part mode: In the Analysis tab, within the Model Report group.

In Mold mode: In the Mold tab, within the Analysis group. In the Analysis tab, within the Model Report group. In the Analysis tab, within the Mold Analysis group.

In the Measure dialog box, you can measure thickness within all solidgeometry or individually selected surfaces. You can specify the following:

Minimum thickness value Checks for minimum thickness. The systemperforms a minimum thickness check based on the value you havespecified. Areas that violate the minimum thickness specified (areas wherethe thickness is less than the specified value) highlight in the model inpurple.


Maximum thickness value Checks for maximum thickness. The systemperforms a maximum thickness check based on the value you havespecified. Areas that violate the maximum thickness specified (areas wherethe thickness is more than the specified value) highlight in the model in red.

Minimum thickness color Specify a different minimum thickness colorthan the default purple.

Neutral color Specify a different neutral color than the default gray. Maximum thickness color Specify a different maximum thickness colorthan the default purple.

Tolerance Specify the allowable error for the calculation. Use post-processing Selecting this check box causes the system to postprocess the results to improve quality and accuracy.

Minimum thickness results display in the graphics window within an on-screenpanel. You can drag this panel as well as collapse it. You can restore it byclicking its on-screen icon.

You can also view minimum thickness results by expanding the Results areaof the Measure dialog box. You can copy and paste the contents of thisResults table to other programs such as spreadsheet applications.

You can save the measurement by clicking Save Analysis from theMeasure dialog box. Save the measurement as either of the following types:

Feature Enables you to save the measurement as a feature in the modeltree.

Analysis Enables you to save the measurement for future use. You canspecify a unique name for the measurement analysis so you can easilyidentify it at a later time. You can retrieve the saved analysis by clickingSaved Analysis from the Manage group in the Analysis tab.

Measurement OptionsWithin the Measure dialog box, you can edit various options by clickingMeasure Options . The following options are available:

Units by Model Units are the same as those of the model. Length Units Specify the desired length units from a drop-down list. Decimal Places Specify the number of decimal places displayed formeasurements.

Show Feature Tab Displays the Feature tab in the Measure dialog box,enabling you to specify regeneration order as well as create parametersfor a given measurement.

Use automatic compute Automatically computes the new measurement ifdifferent references are selected for measuring.

Panel display You can toggle panels to either hide or display them inthe graphics window. You can also toggle panels by collapsing them orexpanding them.


PROCEDURE - Performing a Thickness Check


Analysis\3-D_Thickness 3-D_THICKNESS.PRT

Task 1: Perform a thickness check on a part model.


2. In the ribbon, select the Analysistab.

3. Click Thickness from theModel Report group.

4. Select the 3-D geometry in thegraphics window.

5. In the Measure dialog box, editthe Minimum value to 0.18. Edit the Maximum value to0.50.

Click Compute. Drag the panel approximatelyas shown.

The areas shaded in purpleis thinner than the minimumspecified value of 0.18. Theareas shaded in red arethicker than the maximumspecified value of 0.5.

6. In the Measure dialog box, selectthe Use post-processing checkbox. Click Compute. Notice that the accuracyhas improved in terms ofcolor-coding the model areasthat violate the minimum andmaximum thicknesses.

Click Close.



Module4Mold Models

Module OverviewYou start the mold design process by creating a mold model. You assembleand orient the reference model that represents the design model beingmolded. You can also pattern or assemble the reference part multiple timesto create multi-cavity molds.

In this module, you learn how to create mold models and assemble thereference model into it.

ObjectivesAfter completing this module, you will be able to: Create new mold models. Recognize the differences between absolute and relative accuracy. Locate, assemble, and create the reference model. Learn the different parts of the reference model that you can redefine. Explain the differences between the methods for reference modelorientation.

Explain the different types of mold cavity layout and orientation you can useon the mold model.

Calculate the projected area of the reference model.


Creating New Mold Models

Your company can create customized templates for creatingnew mold models.

A mold model consists of: A reference model Workpieces Mold components Molding

File extension is .asm Use customized moldmanufacturing templates.

Mold templates include: Datums Pull Direction Layers Units Parameters View Orientations

You can modify pull direction.

Figure 1 New Mold Model Tree

Figure 2 New Mold Model

Creating New Mold ModelsA mold model is the model you work on while in Mold Cavity Design mode, orMold mode. The mold model, which has a file extension of .asm, containsthe following:

A reference model. One or more workpieces that represent the overall size of cavity inserts. Several mold components that represent cavity inserts. One molding component that represents the product of the moldingprocess.

The remainder of this course focuses on the creation of these items.

You can create new mold models within Creo Parametric either by usingFile > New, or by clicking New . You can type the name of the mold anddecide whether to use a default template or a template at all. Unless youselect the Empty template, the new mold displays in the graphics windowwith some default datum features.


Using TemplatesYou should create new mold models using a template. Mold templates aresimilar to part and assembly templates in that they enable you to create anew mold with predefined general information. Your company has probablycreated customized templates, as they contain your company's standards.Using a template to create a new mold is beneficial because it means thatregardless of who created it, the mold contains the same consistent set ofinformation, including:

Datums Most templates contain a set of default datum planes and adefault coordinate system, all named appropriately.

Default Pull Direction The direction in which the mold opens. Layers When every mold, part, and assembly contains the same layers, itis easier to manage both the layers and items on the layer.

Units Most companies have a company standard for units in their molds.Creating every mold with the same set of units ensures that mistakes arenot made.

Parameters Every mold can have the same standard metadatainformation.

View Orientations Having every mold contain the same standard vieworientations aids the molding process.

Modifying the Default Pull DirectionThe default pull direction is visible on the model as a double set of arrows,as shown in Figure 2. It is used as a default direction for all mold-specificfeatures and analysis depending on the pull direction. You can toggle the pulldirection display on and off by clicking Pull Direction Display from theIn Graphics toolbar. You can also change the direction of the default pulldirection by clicking Pull Direction from the Design Features group inthe ribbon. The reference you select causes the pull direction to becomeperpendicular to that reference. Keep in mind that if you modify the defaultpull direction within a mold model created using a template, you shouldrename the datum planes appropriately.

The pull direction value is not parametric. This means that featuresbuilt before resetting the default pull direction use the earlierdirection value. They are not updated when you reset the defaultpull direction. Therefore, it is recommended that you do not modifythe pull direction after a certain point in the mold process.


PROCEDURE - Creating New Mold Models


Mold\New CREATE NEW

Task 1: Create a new mold model by selecting a template.

1. Click New from the Quick Access toolbar. Select Manufacturing as the Type and Mold cavity as theSub-type.

Edit the Name to NEW_MOLD. Clear the Use default template check box. Click OK.

2. In the New File Options dialogbox, click Browse. Double-click MMNS_MFG_MOLD.ASM.

Click OK.


4. Notice that an assembly of thesame name as the mold cavity iscreated in the model tree.

5. Explore the default datumfeatures created in the graphicswindow and model tree.

6. Notice the PULL DIRECTION.

7. Click Pull Direction Displayfrom the In Graphics toolbar todisable the pull direction display.

8. Click Pull Direction Displayagain to toggle it back on.


9. In the model tree, click Showand select Layer Tree. Noticethe default layers.

10. Click Show and selectModelTree.

11. Click File > Prepare > ModelProperties to access the ModelProperties dialog box.

12. In the Materials section, clickchange in the Units row. Noticethe units that are set.

13. Click Close > Close.

14. Click Saved Orientationsfrom the In Graphics

toolbar. Notice the default vieworientations.

15. Select view orientation FRONT.

16. Notice that the PULLDIRECTION for the moldpoints upward from the partingplane.

17. Click Saved Orientationsand select Standard

Orientation.

18. Click Pull Direction from theDesign Features group in theribbon.

19. Select datum planeMOLD_FRONT and clickOK from the Pull Direction dialogbox.


Task 2: Create a new mold model by selecting a different template.

1. Click New . Select Manufacturing as theType and Mold cavity as theSub-type.

Edit the Name toNEW_MOLD_ENGLISH.

Clear the Use defaulttemplate check box.

Click OK.

2. In the New File Options dialogbox, select the inlbs_mfg_moldtemplate. Click OK.

3. Again, notice the datum featuresand PULL DIRECTION.

4. Click File > Prepare > ModelProperties.

5. In the Materials section, clickchange in the Units row. Noticethe units that are set.

6. Click Close > Close.



Analyzing Model Accuracy

One of the most important factors affecting the mold designprocess is model accuracy.

Types of accuracy: Relative Absolute

Automatically controllingaccuracy in mold model

Implications of changingaccuracy

When does accuracy need tobe changed?

Figure 1 Confirmation forAutomatically Changing Accuracy

Figure 2 Viewing an AccuracyConflict

Analyzing Model AccuracyOne of the most important factors affecting the mold design process is modelaccuracy. Creo Parametric provides the following types of accuracy settings:

Relative This type of accuracy is specified as a fraction of the longestdiagonal of the bounding box of a model. The default relative accuracy is0.0012.

Absolute This type of accuracy improves the matching of models ofdifferent sizes or different accuracies (for example, imported modelscreated on another system). To avoid potential problems when adding newfeatures to a model, it is recommended that you set the reference model toabsolute accuracy before adding additional parts to the model. Absoluteaccuracy is useful when you are doing the following: Copying geometry from one mold to another during core operations. Designing models for manufacturing and mold design. Matching accuracy of imported geometry to its destination model.

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

Give them all the same absolute accuracies. Designate the smallest model as the base model, and assign its accuracyto the other models.

Automatically Controlling AccuracyYou can perform the following steps to automatically set the correct accuracywhen creating mold models:

Set the configuration file option enable_absolute_accuracy to yes. Create a new mold model. It receives a default (absolute) accuracy value.


Add the first reference model. If a discrepancy exists between theassembly model accuracy and reference model accuracy, the systemissues a warning and prompts you to confirm changing the assemblymodel accuracy, as shown in Figure 1. If you accept, then Creo Parametricswitches the assembly model accuracy from relative to absolute, and setsit to the value corresponding to the accuracy of the reference model. If youdo not accept, the system warns you that there is an accuracy conflict, andgenerates a text file with a *.acc file extension in the working directory.

Create the mold workpiece using the automatic workpiece creationfunctionality. The accuracy of the workpiece is automatically set to be thesame as the accuracy of the assembly model.

Implications and Guidelines of Changing AccuracyWhen you change the accuracy of a model you are changing thecomputational accuracy of geometry calculations. The accuracy of a moldmodel is relative to the size of the resultant molding component. The validrange for accuracy is 0.01 to 0.0001, and the default value is 0.0012.However, the configuration file option, accuracy_lower_bound, can overridethe lower boundary of this range. The specified values for the lower boundarymust be between 0.000001 and 0.0001.

If you increase the accuracy, the regeneration time also increases. Use thedefault accuracy unless you need to increase it. In general, you should set theaccuracy to a value less than half the ratio of the length of the smallest edgeon the model to the length of the largest diagonal of a box that would containthe model. Use the default accuracy until you have a reason not to do so.

Situations for Changing AccuracyThe following are situations that may cause you to have to change accuracy:

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