IMOLD V8: training guide - rayfletcher.net · IMOLD V8 3 What Is The IMOLD Software? IMOLD (for...

IMOLD V8:

training guide

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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.


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.

IMOLD V8

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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.


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


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.


12

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.


14

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.


16

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


18

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.


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

21

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.


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


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


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

23

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


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


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

25

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


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


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

31

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


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


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


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


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.


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.



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.



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


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


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.


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


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…


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


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


Gate Designer, Transform Gate…


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-


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

.


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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61

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.



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

.


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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63

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.


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.


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


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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67



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


Load a moldbase

Add screws

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Page 69

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.

Lesson 5: Moldbase Design

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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71

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.


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


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


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…


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.


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.


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

IMOLD V8

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.


78

13. Unhide/Show

Show all hidden components.



15. Finished.

Save and close the project.

79

Lesson 6 Slider and Lifter Design


Select and position slider body

Select and position lifter body

Create Pockets.

Lesson 6: Slider and Lifter Design

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.


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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83

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.


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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85

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

.


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:

IMOLD V8

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:


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.


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89

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.


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.


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

.


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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91

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.


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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93

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.


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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95

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.


On the IMOLD toolbar, select Save , Save Project... Close the

project.

96

Lesson 7 Ejector System Design


Choose ejector pins

Customize ejector pin diameters

Modify ejector pins

Trim ejector pins

Pocket ejector pins

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97

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 .

Lesson 7: Ejector System Design

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…



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.


100

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


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


Designer, Transform Ejector…

9. Modifying Ejector Sleeves

On the IMOLD Toolbar, select Ejector Designer , Modify

Ejector…



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.


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


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.


On the IMOLD toolbar, select Save , Save Project... Close the

project.

104

Lesson 8 Cooling Design


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.

Lesson 8: Cooling Design

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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107

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.


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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109

Y No 53

X Yes 48

Y Yes 53

X No 9.5


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


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.


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.


Overdrill...

OR


Designer, Overdrill…


114

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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115

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.


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.


Interference…

OR


Designer, Interference…

Front planes of all circuits are coincident.

The end faces are coincident as well.

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117

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


Add standard components

Create pockets for the main inserts.

Add standard components to cooling circuits.

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119

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.

Lesson 9: Standard Components

120

1. Open the Top Level Assembly

Open the SwitchCover project from the Chapter9 folder using Project

Control .

2. Add Locating Ring


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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121

3. Add Sprue Bushing



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.


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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123

5. Add Sprue Puller Insert

Use View Manager , View/Hide… to hide the moldbase, sliders,

lifters and ejectors.



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 .


124

6. Add Ejector Pin.

We will add an ejector pin for ejecting the

sprue.



Component…


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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125

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.


The points are

coincident to

the edges of

the mold

plates.


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.

IMOLD V8

127

9. Create ejector guide location sketch.

Create a sketch on the Front plane of the assembly.


Exit the sketch .

Rename the sketch Ejector Guide Location.


128

10. Create Support Pillar Location sketch.

Create the sketch on the Front plane of the assembly.


Exit the sketch .

Rename the sketch Support Pillar Location.

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129

11. Add Ejector Guides

Start Components Gallery .


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.


130

12. Add Ejector Bushings


Under Placement face, select the ER1 plane under the move_half

subassembly.


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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131

13. Add Support Pillars


Under Placement face, select the SP plane under the move_half

subassembly as the placement face.


Activate Select Sketch and select the Support Pillar Location sketch

Click OK to insert the support pillar.


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…



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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133

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.


Accessory.

-OR-


Designer, Accessory …

Add cooling accessories.

On the IMOLD toolbar, click Cooling

Designer , Accessory...

Under Option, select All circuits.

Click Define button for Nipple.



134

Click Define button for Plug.


Click Define button for ORing.


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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135

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


Purge moldbase.

Create configurations.

Pocketing.

Create drawings.

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137

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


Designer, Utilities, Purge…

Lesson 10: Finishing The Design

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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139

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:


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…


140

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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141

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.


142

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


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


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,

IMOLD V8

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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.

IMOLD V8: training guide - rayfletcher.net · IMOLD V8 3 What Is The IMOLD Software? IMOLD (for...

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