User Guide M Works

MoldWorks 2009 User Guide September 2009
PROPRIETARY RIGHTS NOTICE: All rights reserved. No part of this material may be produced or transmitted in any form or by any means, electronic, mechanical, or otherwise, including photocopying and recording or in connection with any information storage or retrieval system, without the permission in writing from R&B. The information in this document is subject change without notice and should not be construed as a commitment by R&B. R&B assumes no responsibility for any errors that may appear in this document. The software described in this document is furnished under license and may be used or copied only in accordance with the terms of such a license. Copyright 2000-2009 by R&B All rights reserved R&B LTD. 32 Shaham Str. Petah Tikva 49170 Israel
0 Table of Contents
Chapter 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7
Introduction
1-1
System Requirements .................................................................... 1-2 Installing MoldWorks ...................................................................... 1-3 Licensing MoldWorks ..................................................................... 1-4 MoldWork/SolidWorks Compatibility .............................................. 1-5 Steps in Designing a Mold Base Using MoldWorks ....................... 1-7 Special Functions ........................................................................... 1-9 User Interface ............................................................................... 1-10
1.8 MoldWorks FeatureManager Tree ............................................... 1-12 1.8.1 Display Configuration ....................................................... 1-13 1.8.2 Heat Exchange................................................................. 1-14 1.8.3 Runner & Gates................................................................ 1-17
Chapter 2
2.1 2.2
Mold Base
2-1
Coordinate System New Mold
.................................................................. 2-3
................................................................................ 2-4
Chapter 3
Add Plate
3-1
................................................................ 3-2
3.1 3.2
Add Standard Plate Add User Plate
....................................................................... 3-5
Chapter 4
Add User Part
4-1
ii
4.1 4.2 4.3
Insert
..................................................................................... 4-2
Preparing a user-defined component or hole................................. 4-7 User Defined Component or Hole .................................................. 4-9
Chapter 5
5.1 5.2 Slide
Add Slides
5-1
........................................................................................ 5-2
Preparing a user-defined slide ....................................................... 5-8
Chapter 6
6.1 Lifter
Add Lifters
6-1
........................................................................................ 6-2
Chapter 7
7.1 7.2
Heat Exchange
7-1
Insert Cycle
............................................................................. 7-2
Positions ......................................................................................... 7-3
7.3 Cycle............................................................................................... 7-4 7.3.1 Cycle Pipe(s) ...................................................................... 7-5 7.3.2 Components ....................................................................... 7-6 7.3.3 Additional Parameter(s) ..................................................... 7-7 7.4 Modification .................................................................................... 7-8 7.4.1 Edit Cycle ........................................................................... 7-9 7.4.2 Add Component ............................................................... 7-10 7.4.3 Edit Pipe ........................................................................... 7-11 7.4.4 Edit Component................................................................ 7-12 7.5 Settings......................................................................................... 7-13
Chapter 8
Runners & Gates
8-1
8.1 Insert Runner System .............................................................. 8-3 8.1.1 Positions............................................................................. 8-4 8.1.2 Parameters......................................................................... 8-5
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8.2
Insert Gate(s)
........................................................................... 8-8
8.3 Modification .................................................................................. 8-12 8.3.1 Edit System ...................................................................... 8-13 8.3.2 Edit Runner ...................................................................... 8-14 8.3.3 Add Gate .......................................................................... 8-15 8.4 Settings......................................................................................... 8-16
Chapter 9
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9
Add Component
9-1
Steps to add a component ............................................................. 9-4 Component Rule Implementation................................................. 9-13 Component Naming ..................................................................... 9-15 Guide Pin Guide Pin2 Leader Pin Leader Pin2 Bushing Sleeve .............................................................................. 9-16 ........................................................................... 9-17 .......................................................................... 9-18 .................................................................... 9-20 ............................................................................... 9-21 ............................................................................... 9-22
9.10 Angular Pin 9.11 Cap Screw
....................................................................... 9-23 ............................................................................ 9-24 .............................................................. 9-26 .................................................................. 9-28
9.12 Countersunk Screw 9.13 Shoulder Screw
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9.14 Set Screw 9.15 Ejector 9.16 Ejector Pin
........................................................................... 9-30 .................................................................................... 9-31 ............................................................................ 9-32
9.17 Ejector Sleeve 9.18 Flat Ejector 9.19 Ejector Locks
................................................................... 9-34 ........................................................................... 9-36 ......................................................................... 9-38
9.20 Ejector Trim .................................................................................. 9-39 9.21 Stop Pin 9.22 Stop Disc 9.23 Spru Bushing 9.24 Locating Ring 9.25 Support Pillar 9.26 Dowel Pin ........................................................................... 9-41 ............................................................................ 9-42 ....................................................................... 9-43 ................................................................... 9-44 ...................................................................... 9-46 ............................................................................... 9-47 .................................................................. 9-49
9.27 Tubular Dowel Pin 9.28 Lifting Hole
.......................................................................... 9-51 ....................................................... 9-52
9.29 Tapered Interlock Male
9.30 Tapered Interlock Female
................................................. 9-54 ................... 9-56
9.31 Shoulder Plate 1 (Countersunk screw head) 9.32 Shoulder Plate 2 (Cap screw head) 9.33 Air Valve 9.34 Spring 9.35 Stamps
................................. 9-57
............................................................................... 9-58 ............................................................................... 9-59 .............................................................................. 9-60
9.36 Add Cooling .................................................................................. 9-62
9.37 Cooling Type 1 9.38 Cooling Type 2 9.39 Cooling Type 3 9.40 O-Ring1 9.41 O-Ring2
................................................................... 9-63 ...................................................................... 9-64 ....................................................................... 9-65
.............................................................................. 9-66 ............................................................................. 9-67
Chapter 10 10 Edit
10.1 Edit Component Sketch 10.2 Modify Parameters 10.3 Attributes 10.4 Delete
10-1
......................................................... 10-2 ............................................................... 10-3
............................................................................... 10-5 .................................................................................... 10-6 ........................................................................... 10-8

vi
10.5 Recalculate
10.6 Mold Size
.............................................................................. 10-9
Chapter 11 11 Utilities
11.1 Collision
11-1
................................................................................ 11-2 ................................................................... 11-4 ................................................ 11-7
11.2 CNC Information
11.3 Hide/Show Mold Components 11.4 2D Drawings
...................................................................... 11-8
11.5 User defined templates for 2D Drawings ..................................... 11-9 11.6 Options.................................................................................... 11-10 11.6.1 Plate Options.................................................................. 11-11 11.6.2 Component Options ....................................................... 11-12 11.6.3 General Options ............................................................. 11-13 11.6.4 Rules Options................................................................. 11-14 11.6.5 PDM Options .................................................................. 11-15 11.7 Injection Machine ................................................................ 11-16
11.8 Injection Machine Data............................................................... 11-17 11.9 Operations Report ............................................................... 11-19
Chapter 12 12 B.O.M. Chapter 13 13 Convert Catalogue
12-1 13-1
13.1 Converter...................................................................................... 13-2 13.2 Component EXCEL file format ..................................................... 13-3
Chapter 14 14 Help
14-1
vii
1
1 Introduction
MoldWorks is mold design software imbedded in SolidWorks. It has been conceived to free mold designers from tedious work such as creating mold plates and components, as well as detailing slots and holes within the mold plates.
MoldWorks is much more than a 3-D Solid based mold library; it is an Object Oriented Parametric Application. Its different components are defined by their degrees of freedom, including geometric information and relative positioning of parameters.
MoldWorks2009 User Guide
1-1
Introduction
1.1
System Requirements
MoldWorks is fully integrated under the SolidWorks environment thus system requirements are similar to those of SolidWorks. Hardware Since MoldWorks creates relatively large assemblies we recommend using the optimum hardware recommendations from SolidWorks. Operating System Windows XP /Vista(r) 32 or 64bit. Windows XP /Vista(r) 32 or 64bit. MoldWorks current version is MoldWorks 2009. SolidWorks current version is SolidWorks 2009. Adobe Acrobat Reader 5.0 or higher. Networks Required Software
Licensing MoldWorks is protected using a software license system FLEXlm (FLEXnet Publisher Licensing Module), which allows both an individual standalone license (locked to a workstation) and floating licensing (across a network) without the need for a dongle.
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Introduction
1.2
Installing MoldWorks
A user must have administrator privileges to install MoldWorks. Make sure that SolidWorks is not running during the installation. The MoldWorks installation can be initiated from a CD or from an executable file downloaded from the R&B web site (www.RnBUSA.com) Once the installation is completed, logon as the user and activate SolidWorks. You may have to add MoldWorks to the SolidWorks add-ins using the SolidWorks > Tools > Add-ins menu.
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Introduction
1.3
Licensing MoldWorks
R&B uses the FLEXlm (FLEXnet Publisher Licensing Module) license manager for all of its licensed products. This is a separate module allowing licensing on a node locked or floating (server/client) basis. If this is an initial installation (i.e. the current MoldWorks products have never been installed on this workstation) a message box will pop up which allows you to make a license request by clicking on the Register button. A license request can also be made at any time through the MoldWorks > License Registration menu or from the Start > R&B > License> R&B License Manager. Refer to the R&B License Guide for details on how to fill out and send the license request. If you have no license or the license has less then 30 days left then a similar message box will appear as follows:
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Introduction
1.4
MoldWork/SolidWorks Compatibility
Following is a list of functions within SolidWorks, which affect the MoldWorks application. Tools > Options MoldWorks will set certain options from the SolidWorks Tools > Options menu during its operation. These options always will be returned to the user default. They include: Under the General tab: - Input dimension value: not checked. - Save AutoRecover Info every: not checked. Under the External References tab: - Allow multiple contexts for parts when editing in assembly: checked Under the Detailing / Annotation tab: - Feature dimensions: not checked. Visible Each part in SolidWorks has the property to be Visible (default) or not Visible. This property may be defined by right-clicking the mouse when a part is selected in the FeatureManager design tree or on the graphic screen. MoldWorks will not function on a Plate (or Insert), which is Hidden only Shown. A part is hidden or shown by pointing at it in the FeatureManager design tree and using the right-click button on the mouse, which accesses the Hide or Show menu. This is a useful tool in order to reduce the compute time for MoldWorks functions. For example if a user-defined component is integrated within the mold, the application will check only the plates, which are shown before cutting thereby considerably shortening the compute time. A plate, which, was not cut by a component or pipe because it was hidden, can be recomputed. After making the plate shown just edit the components, which should have cut it, with the MoldWorks > Edit > Modify Parameters on the edit component menu or relevant icon and select dialogue box. The plate will then be recomputed taking into account these components.
1-5
Introduction UNDO The UNDO (Ctrl+Z) function does not work coherently with MoldWorks; it has been deactivated when using MoldWorks functions.
1-6
Introduction
1.5
Steps in Designing a Mold Base Using MoldWorks
After the design of a plastic part in SolidWorks the core and cavity inserts are extracted from the part geometry using the SplitWorks and SolidWorks tools. These inserts have all the part information, including draft angles and dimensions, to produce the part using the injection molding process and will be integrated into the MoldWorks application. 1. The first step is to define the Mold Coordinate System. The MCS (previewed in blue) is defined using a plane (defaults to the Top Plane) as the parting plane of the mold. The actual middle of the mold, and its orientation may then be defined using the dialogue box controls. 2. Next is to set up the mold, including naming of the different assemblies, identification of the cores, cavities and creation of side cores, which are to be fitted into the mold, adding user-defined descriptive information for output to the bill of materials. This step allows MoldWorks to automatically estimate a mold size according to default (user modifiable) plate rules. This is optional and may be performed after the creation of the mold base. 3. You can create an initial mold base with one of the following four options: - A standard mold base consisting of nine plates or a non-standard mold base (created by changing the plate sizes) depending on the selected options. Components are automatically located and placed according to specific catalog definitions that you choose. Plate thickness and additional component selections can be applied prior to the creation of the mold base using parametrically driven graphical input. You then create the 3D solid mold base by the click of a button. - Non Standard Start with a standard mold base size then change 4 global parameters to define non-standard dimensions of the mold base. The component dimensions are created according to the standard size selection. The component positions are stretched so that the positions of the components from the plate edges stay the same. - Plates Only to create only the plates and not the components or component holes. - You can create a plate assembly with User Plates that are standard parts created within SolidWorks. The functionality of MoldWorks will be the same as if a standard mold base has been created. - You can create a combination of Standard Plates and User Plates and add more standard plates.
MoldWorks2009 User Guide 1-7
Introduction 4. Add cavity inserts to the mold (for inserts that were not selected in the first step) 5. Add Standard or User Defined components - Retrieved from standard catalogs, components such as screws, ejector pins, cooling lines, and so on, are added to complete the design of the mold base. You can define the characteristics of the components, including dimensions and location, and then place them into the mold base. Also you can use any part created within SolidWorks as a User Defined component, functioning as if it was created as a standard MoldWorks component. 6. Create cooling cycles with the Heat Exchange module. This module allows you to use 2D and 3D sketches to define the cycle(s) and automatically preview them and allow you to browse through the cycles and change technological information regarding the pipes and components. The result creates a technological tree which allows modification of the elements of the cycle at every level. 7. The Runner & Gates module works in a similar fashion creating runner systems from sketches allowing you to define the runner shapes through a dialogue including all the relevant parameters with instant on screen preview. Gates are added either connected to the runners or as separate entities. 8. Modify Components and Mold size By selecting a component or its locating hole in one of the plates you can modify the parameters of a component and/or groups of components. Components can also be deleted or repositioned. You can modify the attributes of the different mold base parts (i.e. the information which is written into the BOM). A global change of the mold plates dimensions can be done at any stage of the mold design process. 9. Output to the mold maker You can output the CNC technology file as well as the Bill of Materials (through the drafting routines) as an integral part of the production process. In addition to the BOM information, you can create detailed drawings using the SolidWorks drafting mode. Plate geometry, including all of its components, can be detailed and delivered to the mold maker for final mold production.
1-8
Introduction
1.6
Special Functions
In addition to the basic functionality, which was described in the previous section MoldWorks has special functions in order to allow you to create a complete mold including the following tools: Add Plate: To add a standard or non-standard plate. A part created by SolidWorks can also be used as a plate. In this way you can use MoldWorks to design Progressive Dies, Blow Molds, Jigs and Fixtures, etc. Add User Part: You can use this tool to integrate the inserts into the mold base. You can also integrate user components i.e. use any part created within SolidWorks as a component. In this way you can integrate components not included in the catalogues (i.e. hot runners) and specific homemade components within the mold base. Utilities: To output CNC technological file, check collision or thin walls between components, inserts and plate faces and hide or show all the components in one action. Options: To set the names and colors of components and plates, colors of component holes and default catalogue as well as default mold type... This information is stored in the registry to be used in subsequent mold creation. Heat Exchange Module: A complete module allowing creation of cooling cycles from 2D and 3D sketches, including its own Technological Feature Tree with RHM button menus for modification at all levels. Runners & Gates Module: A complete self contained module for the creation of runners and gates from 2D (and 3D) sketches, including its own Technological Feature Tree with RHM button menus for modification at all levels.
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Introduction
1.7
User Interface
MoldWorks uses a unique user interface so that you are guided through every step of the mold design process while allowing you to modify any step previously defined without having to begin the process from scratch. Most of the menus (Except NEW MOLD which works under the New Property Manager) display a control dialogue box from which the steps of the design process are displayed. Following is an example of the Add Component control dialogue box: The top level of the control box includes the icons for the different steps to complete the task, in this instance to add a component. The bottom level of the control dialogue box is the same for all and includes the Create, Create and New, and Cancel icons. This dialogue box is displayed throughout the whole process. Each top-level icon displays a dialogue box whose appearance depends on the step. Here is an example of the dialogue box displayed when of this control dialogue box is the first icon pushed (by default it opens immediately). This dialogue box allows you to choose the component that is to be created from the component library. Every dialogue box has the icon. This icon guides you to the next step of the design process. Alternatively you may just press the next icon in the top level of the control dialogue box. The steps can be created in any order (if enough data exists) and any step that you have already created can be accessed through the top level at any time and modified before the process is complete.
Introduction Once you have completed all the steps only the control dialogue box will remain displayed on the screen. If you are satisfied with the parameters and data that you have entered in the dialogue boxes, (generally you will see a dynamic preview of the parts that are to be created), then activate the creation process using the following icons. Activate the process and close the control dialogue box. Activate the process and leave the control dialogue box displayed while initializing the data. Cancel the process and close all the dialogue boxes. NOTE: The graphics we use in this User Guide have mixed styles between classic Windows 2000 and new Windows XP.
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Introduction
1.8
MoldWorks FeatureManager Tree

.
The MoldWorks FeatureManager tree appears after an initial mold is created through the MoldWorks > New Mold menu or by clicking on The MoldWorks FeatureManager tree contains a Display Configuration folder in order to organize the display or suppression of various mold configurations a Heat Exchange folder to organize the cooling cycles and cooling cycle menus and a Runners & Gates folder to organize the runner systems and gates.
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Introduction
1.8.1 Display Configuration

This folder is useful when adding components, since it allows you to concentrate on the specific display suitable to the component being created. MoldWorks only cuts the plates (or inserts), which are visible (and of course not suppressed). Parts which are not visible are not taken into account when adding components, helping to achieve better performance. Furthermore parts which are suppressed are not resident in memory, which is useful when working on complex molds. MoldWorks automatically displays (or resolves) mold parts when necessary (i.e. when modifying components plates or inserts will be resolved and/or displayed if relevant). The Display Configuration tab allows you to easily create SolidWorks Configurations. After the creation of an initial mold base MoldWorks adds a Display Configuration folder to the MoldWorks FeatureManager tree allowing the user to Show Only/Resolve Only different configurations of the mold assembly using the RHM button menu.
1-13
Introduction
1.8.2 Heat Exchange

This folder organizes the data (in folder form) and the menus enabling you to create and modify cooling cycles. There are three levels of folders under the Heat Exchange heading: Data Cooling Cycle for each cooling cycle defined. Pipe name for each pipe segment with the Cycle Component name for each component connected to a pipe.
Selecting a folder or component will highlight the relevant geometry on the screen.
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Introduction Menus The complete menu environment for the Heat Exchange functionality is accessed from the MoldWorks FeatureManager by clicking the RHM button on the relevant folders, cycles/pipes or components. The Heat Exchange folder accesses the Insert Cycle menu to begin the process (also available through the MoldWorks > Insert Cycle or relevant icon.) and the Settings menu to define parameter values for subsequent use.
RHM button on the Cooling Cycle folder accesses the following menus:
These menus are used to manage the Cooling Cycle data.
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Introduction The Pipe and Component environment have their own context sensitive menus:
RHM click on a pipe segment
RHM click on a component
Check out the Modification section in the Heat Exchange chapter for detailed menu descriptions.
1-16
Introduction
1.8.3 Runner & Gates

This folder organizes the data (in folder form) and the menus enabling you to create and modify runners & gates. Data Runner System for runner system. Runner for each runner segment within the runner system. Gate for each gate created within a Runner or separately if the gate is not created from an end point of a runner sketch.
Selecting a folder or component will highlight the relevant geometry on the screen.
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Introduction Menus The complete menu environment for the Runner & Gate functionality is accessed from the MoldWorks FeatureManager by clicking the RHM button on the relevant folders; Runner System, Runner and Gate which represent the different technologies of the system. The Runner & Gates folder accesses the Insert Runner System and Insert Gate(s) menus to begin the process (also available through the MoldWorks > Insert Runner System and MoldWorks > Insert Gate(s)or relevant icons) and the Settings menu to define parameter values for subsequent use.
RHM button on the Runner System folder accesses the following menus:
These menus are used to manage Runner System data.
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Introduction Each Runner and Gate (with or without a Runner) are managed through the following menus:
RHM click on a Runner
RHM click on a Gate
Check out the Modification section in the Runner & Gates chapter for detailed menu descriptions.
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2
2 Mold Base
The MoldWorks > Mold Base > Coordinate System menu or relevant icon enables you to define the mold base coordinate system, i.e. the direction of the plate assembly. The MoldWorks > Add User Part menu or relevant icon define the inserts to be included within the mold base. allows you to creates
The MoldWorks > Mold Base > New Mold menu or relevant icon the initial mold base.
Prior to this stage you should have created the core and cavity inserts using SplitWorks or the standard SolidWorks tools, or by importing external geometry, in any case an initial mold can only be created within a previously saved assembly. The inserts must be coherent SolidWorks parts or subassemblies. The initial mold base can be created with or without components by adjusting the Type: parameter in the dialogue box to Standard, Non-Standard or Plates Only respectively. The Non-Standard and Plates Only types allow the user to change the mold dimensions (width and length) as well. MoldWorks standard mold base is based on a 9 plate standard mold as defined in the commercial mold industry catalogues. Catalogues are sometimes divided in Series, and each series will have a completely separate definition. With the Plate Configurations icon the different standard configurations can be chosen depending on the catalogue. For certain catalogues you can choose to not have the Top Clamping plate or the Support plate or both. Once you have a suitable mold size the mold plates, initial components are automatically created according to the selected catalogue definitions. Component positions for the Non-Standard and Plates Only type are automatically calculated according to the distance to the corner points of the plates. The plate assembly is created by mating between the plates and equations constraining the dimensions within each plate, and constraining the complete plate assembly to 4 sketches (Base Plate/Raiser Plates/Ejector Plate). These sketches and equations facilitate editing of the initial mold base
Mold Base even after the mold tool has been created.
2-2
Mold Base
2.1
Coordinate System
This is the Mold Coordinate System dialogue box which appears when the MoldWorks > Mold Base > Coordinate System menu or relevant icon is picked, allowing you to define the plane and the origin on which the mold base will be created. Selected Plane/Coordinate System: Choose a Plane or Coordinate System on which to create the mold base. The default is Plane 2. Plane. The Mold Direction is defined as the positive normal to the selected Plane and the Mold Origin is the default origin of the assembly. Coordinate System. The Mold Direction is defined as the z-direction and the Mold Origin as the origin of the Coordinate System.
Origin Placement Type the value that will determine the origin of the plates from the origin as determined in the previous section. Defaults to (0,0). Rotate Rotate the Coordinate System in the plane by increments of 90 degrees. Z Axis flip Flip the direction of the Coordinate System relative to the Selected Plane. This menu (icon) is available only before creation of a new mold base. The Coordinate System of the mold base may not be modified after the mold has been created.
2-3
Mold Base
2.2
New Mold
This is the New Mold dialogue box, which appears when the MoldWorks > Mold Base > New Mold menu or relevant icon is picked, which allows creation of the initial mold base. A preview of the mold base is displayed and dynamically updated each time a parameter is modified. The current display is automatically adjusted to fit the mold base. The Dialogue Box is divided into the following groups: Catalogue group defines the catalogue specifications. Thickness group accesses the thickness for each plate. Mold Dimensions group to define the plate layout dimensions (Non-Standard and Plates Only). Options group controls which of the initial components will be created. Estimation group accesses the Plate rules. (Cores and/or cavities have been defined through the MoldWorks > Add User Part menu). Injection Machine allows the display of both the Standard and User Defined Injection Machines. Groups are accessed exclusively; only one tab can be open at any time. Following is a detailed description of the New Mold dialogue parameters according to the different groups.
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Mold Base Catalogue Name: Window to select specific mold base library. All the catalogues for the specific unit (i.e. mm or inch) will be displayed. You will be able to load ONLY the catalogues for which you are licensed. The catalogue you choose when creating the initial mold base will be the default catalogue for this mold; a different catalogue may be designated each time a new component is created. Series: Select specific series (displayed only if different series for this catalogue exist) Type: Specify which type of initial mold base you require: Standard is with initial components and initial component holes. Non-Standard the same as Standard allows the user to define the Mold Dimensions as well. Plates Only creates only the plates and the sketches defining the standard positioning. This option is useful when a non-standard mold base is required.
Click on this button to change the plate configuration. The plate configurations depend on the selected catalogue. Here is an example of the plate configurations for the Training catalogue.
Dimensions: Choose a standard dimension from the available list by picking in the scrollable list that is displayed when pointing to the arrow on the right-hand side of the
Mold Base Dimension box. The list will contain the standard mold base sizes as defined in the chosen catalogue. For each standard dimension there is a set of plate thickness, which is automatically updated and shown in the Plate Thickness parameter box.
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Mold Base Thickness This group box includes the thickness for each standard plate. The plates are numbered from 1 to 9 or according to the specific catalogue for new and modified catalogues. The plate thickness dimension symbol in the dialogue can be changed via MoldWorks > Utilities > Options. The drop down buttons on the right-hand side of each thickness enables you to choose a standard size from the catalogue. The scroll box for SA (gap between Plate2 and parting line) and SB (gap between Plate3 and parting line) enables you to scroll to the required gaps. In the case of a Non-Standard or Plates Only mold type then plate thickness can be scrolled or keyed-in. Press in order to see the position of each plate.
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Mold Base Mold Dimensions (Non-Standard and Plates Only) This section contains the 4 parameters describing the general layout of the plates. They default to the dimensions as dictated by the specific mold base size selected in the Dimensions parameter box. New values can be keyed-in to create a non-standard mold base. The positioning of the components (or positioning sketches for Plates Only option) is dictated by their distance to the corner points of the plates and will be adjusted according to the A and B parameters. Press to return to the default values.
to display graphic help of the Press plate layout parameters.
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Mold Base Options (Standard and Non-Standard)
Components, which are marked, will be created at the initial stage. The actual component options differ for each library as well as the default initial choice. For a Non-Standard mold where the user has changed the plate thickness for which a relevant standard component does not exist, the component will not be created. The preview for this component will be highlighted in red. Certain catalogues have more then one option for the Clamping Plate (i.e. Meusberger) so we have added a drop list.
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Mold Base Estimation This group contains the Plate Rules that guide the automatic mold base estimation, which is based on the inserts defined in the Add User Part menu (and Sliders if initially defined). Dimension: This is the same parameter from the Catalogue tab, and is displayed here for convenience in order to help adjust the estimation parameters. Press to save parameters S1, S2, T1 and T2 (parameter S3 is calculated). Press to display graphic help of the parameters.
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Mold Base Description of the Estimation Parameters S1: The height Cavity + this parameter dictate the size of Plate2. S2: The height of the Core and Other inserts + this parameter dictate the size of Plate3. S3: This parameter is calculated according to the height of the Core and Other, and is adjusted to dictate the size of Plate4 and Plate5. T1: The size of the inserts + this parameter decide the standard length dimension of the mold. T2: The size of the inserts + this parameter decide the standard width dimension of the mold.
On validation the mold base will be created as an assembly of plates. The plates will be created as SolidWorks parts with the names Plate1 to Plate9. Plate names can be changed under the Plate tab in the MoldWorks > Utilities > Option before creating a new mold. After the mold creation plate names must not be changed. This action will take a few minutes depending on the speed of your workstation. While the system is building the mold base you can see the plate definitions in the FeatureManager Design Tree window under the names PLATE1_1 to PLATE9_1. In order to speed up the process we hide all the visible parts in the assembly at the beginning of the process and return them to their default status at the end. If Type: is Standard or Non-Standard then MoldWorks creates the initial components and component holes in the plates. Only one component per group is displayed (the others are instances and not displayed) If Type: is Plates Only then a 2D layout of the holes and positioning of the initial components is created as sketches on the middle plane of the mold base.
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Mold Base
Injection Machine Click on this button to get a preview of the current Injection Machine.
Manufacturer: Select a manufacturer. Size: Select a size. Display Injection Machine: Check this parameter to display the injection machine during the initial mold definition. The Injection Machine can also be displayed at any time after the initial mold creation through the MoldWorks > Utilities > Injection Machine menu.
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3
3 Add Plate
This chapter deals with the functionality to add standard or user plates (a user plate can be any SolidWorks part) to a mold base (MoldWorks > Add Plate or relevant icon). Standard Plate This option creates a new plate similar in geometry to a reference plate while allowing control of its dimensions, position and attributes. Useful for adding insulation plates, stripper plates etc. The original plates of the mold base are automatically moved to take into account the new plate. This option will be available only if an initial mold base exists. Important: After a standard plate has been added, the system automatically checks component(s), which pass through the newly created plates, and opens the MoldWorks > Edit > Recalculate dialogue with the components, which have been affected, allowing the user to decide whether to modify them or not. After the user has made the modifications the mold base is recalculated. User Plate With this option you can add any SolidWorks part to the mold base as a plate or build your own mold base from scratch with any SolidWorks parts. MoldWorks functionality will work on this mold base as if it was created with the standard New Mold menu. The original plates of the mold base are not adjusted.
3-1
Add Plate
3.1
Add Standard Plate
The Standard tab on the Add Plate dialogue box, which appears when the MoldWorks > Add Plate menu or relevant icon is picked, allows creation of extra standard plates on condition that an initial mold base already exists. Add Plate is the controlling dialogue box, which guides you through the steps to create a standard plate, while allowing you at any stage to modify previous data without having to restart the process. Accesses the Plate Dimensions dialogue box. Accesses the Placement dialogue box.
Reference plate: Select a reference plate by picking on the plate or in the FeatureManager Design Tree. A new plate is previewed above the reference plate with the same dimensions as the reference plate. The Length: Width: and Height: parameters are filled in with the new plate dimensions and can be modified. Each time a new plate is selected the parameters are dynamically modified.
Click on the Attributes icon to access the Part Attributes dialogue box.
3-2
Add Plate
By default the new plate attains the attributes of the reference plate. Each parameter may be modified. This data is written into the parts Summary Info under the Custom tab, which you can see and add by activating File > Properties in a Part window. Create or Cancel definition. the new attribute
Click the icon or Placement access the Placement dialogue box. By default Move Plates is checked. If not then MoldWorks does not adjust the other plates to accommodate the new one. Connected Face
to
Choose to connect to the Top Face or Bottom Face of the reference plate. Alignment on face If the dimensions of the new plate have been modified then you can position the new plate along one of the sides of the reference plate using the directional arrows.
3-3
Add Plate DX/DY Offset the new plate from the center of the reference plate. Press to return to the controlling dialogue box.
Press the Create button to create the new plate and commence the Recalculate function, refer to Chapter 9.5 for more details. Press the Create Without Recalculate button to create the new plate and allow more plates to be added. In this case no recalculate takes place. Press the Cancel button to cancel the process.
3-4
Add Plate
3.2
Add User Plate
In order to add SolidWorks parts as User Plates in MoldWorks the parts have to be created, saved and positioned in the mold assembly before starting the menu. Activate the menu MoldWorks > Add Plate(s) or the relevant icon. The following dialogue box is displayed (unless an initial mold base exists, in which case the Add Plate dialogue box will include the Standard tab as well). This is the controlling dialogue box that guides you through the steps to create user plate(s).
Accesses the Add User Plate(s) dialogue box. Click on box. to open the following dialogue
User Plate Selection Select SolidWorks part(s) by picking on the part or in the FeatureManager design tree. Select a plate in the area and click on this button to define the plate attributes. (The data is written into the parts Summary Info under the Custom tab which you can see by activating File > Properties in a Part window) Press to return to the controlling dialogue box. Press the Create button user plate(s). to integrate the
3-5
4
4 Add User Part
In this chapter we deal with the functionality of adding external SolidWorks parts to the mold base as inserts, components or holes. Once a part has been added to the mold base as a component it will function as a standard MoldWorks component. Inserts will function similarly to plates however we add them through this menu in order to allow the creation of a pocket with the insert. Before activating the Add User Part menu the appropriate sketches or parts should be created depending on the use of the function. You can create special components, which dont appear in the catalogue and integrate them through this function into the mold base. Specifically as an example hot runners are not included in the MoldWorks catalogue due to their diversity and the fact that they are usually not standard. These hot runners can be easily created within SolidWorks and integrated through this function. Insert can be grouped in a sub assembly and added with one selection by selecting the subassembly after it is positioned in the mold assembly. The assembly may contain parts to create the inserts pockets by a cavity operation. The names of the parts to create the pockets must be prefixed by _T (example: CorePocket_T). The system will then recognize the pocket cutting tools automatically.
4-1
Add User Part
4.1
Insert
To add inserts activate MoldWorks > Add User Part menu or relevant icon. The behavior of this dialogue depends on whether an active mold already exists. This is the controlling dialogue box that guides you through the steps to create an insert, while allowing you at any stage to modify previous data without having to restart.
Accesses the Insert In-Place dialogue box. The next group of icons controls the type of pocket to be created for the insert. It is active only if a mold already exists. Only one of them must be chosen. Accesses the dialogue box to create a pocket from an existing part. Accesses the dialogue box to create a pocket from a sketch. Informs MoldWorks that no pocket is to be associated with this insert. (Default if neither of the 2 preceding options is chosen)
4-2
Add User Part
Click on the
icon and the following dialogue box is displayed: Before mold exists
Active mold exists
Insert list Select SolidWorks part(s) or assemblies from the Feature Manager Design Tree. Only one part for each instance will be displayed. Select a part and click on this button to define the insert attributes. The None/Other/Core or Cavity parameter type is set according to the type of insert for each part, the default Insert type is set to None. Each part in the list can be defined with a different insert type. Before an active mold exists this dictates the mold estimation calculation. Press active mold exists). to close this dialogue box and move to the next step (if
Before an active mold exists, cutting tools (i.e. parts included in the insert subassemblies suffixed with _T) will be automatically activated on the relevant mold plates at the end of the mold creation process.
Add User Part Active mold exists For the next step choose one of the following: Solid Pocket Icon will display the following dialogue box:
Solid List Select SolidWorks part(s) that will be used as the cutting tool(s) by picking on the part or in the FeatureManager design tree. These parts must be in the current assembly. If the insert(s) are assembly(s) containing parts or assemblies with names suffixed by _T (example: CorePocket_T) they will be detected automatically as pocket cutting tools, and appear in the dialogue. If they do not automatically appear, then select the insert assemblies from the Feature Manager Design Tree and the tools will then appear here. Press to close this dialogue box and move to the next step or
to complete the operation.
4-4
Add User Part
Pocket By Sketch icon
will display the following dialogue box:
Selected Sketch Select a sketch that will be used as the extrusion profile by picking on a sketch or in the FeatureManager design tree. The sketch must be part of the tree of the Plate that is to be cut. It must be created on the face of the Plate. Pocket depth The following four options can be selected for the pocket depth: Blind Key-in or scroll to input a value or pick an edge and select . The length of the edge will be recorded in the Depth box. Through All Creates a pocket through the plate, which contains the sketch. Up To Vertex Creates a pocket up to a vertex (but only as deep as the plate). Up To Face Creates a pocket up to a face (but only as deep as the plate).
Press
to close this dialogue box and move to the next step or
to complete the operation.
4-5
Add User Part
to indicate to the system that there is no pocket No Pocket icon associated with this insert or the user will add the pocket separately using SolidWorks tools.
At this stage the following dialogue box displayed:
Correct any of the previously defined steps or press the Create button integrate the insert or press the Create and New button insert and remain in the menu.
to
to integrate the
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Add User Part
4.2
Preparing a user-defined component or hole
In order to create a user-defined component (or hole) the first step is to create a SolidWorks part that represents the component (or hole). The reference coordinate system of the part is SolidWorks part coordinate system at the part origin. The part origin is the reference point of the part and SolidWorks Z direction is the principal direction of the part. Create a set of configurations to represent the different sizes of the component (or hole) using the Insert > New Design Table menu (see SolidWorks Users Guide). Add to the Part File properties in the Custom tab under the Summary Information dialog box the following properties: Symbol Description Material Heat Treatment You can also prepare a pocketing tool corresponding to the user-defined component. This tool must also be a SolidWorks part and fulfill the following conditions: It must be saved in the same folder as the component. If it has a tool then: 1. It must have the same name, as the component with the addition of _T. i.e. if the name of the component is NZL.SLDPRT then the name of the tool must be NZL_T.SLDPRT. (See an example in the Hotrunner folder under examples in the MoldWorks installation) 2. It must have the same number of configurations, and each configuration name, the same as the configuration name in the component part file. You can create a user-defined hole in the same manner as the tool for the component, which, in this case there will ONLY be a tool (_T) without a component.
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Add User Part Component Tool
4-8
Add User Part
4.3
User Defined Component or Hole
Add a user-defined component/hole or group of components/holes. Activate MoldWorks > Add User Part menu or relevant icon. Click on the Component or Hole tab and one of the following dialogue boxes appears.
The following applies to components (with or without tools) or holes without components. The component and tool for the component case or tool for the hole only case will be copied to the mold folder before being placed in the mold. The user can decide whether to copy or instance a component or hole for each position point in the mold. This is the controlling dialogue box that guides you through the steps to create a user-defined component or hole, while allowing you at any stage to modify previous data without having to restart.
Accesses the User Component Library dialogue box. Accesses the Import User Component dialogue box. Accesses the Start Face dialogue box to pick the face on which to place the component(s). Accesses the Component Positioning dialogue box.
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Add User Part
Click on the
icon and the following dialogue box is displayed:
to display only the user components/holes for a chosen library Click on the (and to expand the dialogue). This dialogue is used to define new user component library folders (see next section) and/or choose a user component. For the Component only the user component will be shown (not the tool i.e. not the parts suffixed with _T) and for the Holes only the tools (i.e. parts suffixed by _T) will be shown. The default folders are under the MoldWorks\UserComp folder and appear with a lock next to them to show that they are protected. System or default libraries are placed here to protect them from accidental removal. The user component (or hole) folders will exist for subsequent sessions of MoldWorks. You can delete a folder from the folder list by selecting it and pressing the delete button.
or click twice on a user Select a user component and press component to access the next Import User Component dialogue.
Add User Part Define a new user component library Click on the palette. icon to add folders to the user component library
Choose a folder with user components as defined in the previous section, and click OK to add it to the user component library. The new folder will now appear in the left hand window of the User Component Library dialogue.
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Add User Part
Import User Component
MoldWorks automatically reads in the part, displays it in the window and shows its configurations in the Select configurations list box. Selected Configurations Select a configuration from the Selected Configurations list box. Options Click on this icon if you want an instance of the component at each positioning point. Click on this icon if you want a copy of the component at each positioning point. (This is useful if you want to do manipulations on each component separately i.e. cut an ejector up to a surface.) Click on this icon if you want a pocket to be created for the component. This means that a tool with the component name suffixed by _T exists in the folder with the user component, otherwise MoldWorks will ignore the pocket. Complete the attribute definition. Press to close this dialogue box and move to the next step.
Add User Part
Start Face
Select the starting face of the Plate/Insert on which the component(s) is placed. The component is fixed to the specific Plate/Insert and subsequent modifications to the Plate or Insert will affect the component(s). This is the face on which the positioning sketch (defined in the next step) is projected.
Press
to close this dialogue box and move to the next step.
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Add User Part
Component Position Selected sketch Select or create a sketch that will be used as the positioning profile by picking on a sketch or in the FeatureManager design tree. If the sketch is created on the fly, then when it is closed it will be listed in the Selected Sketch list box automatically. V. Dev (-90 to 90 degrees) is the angle from the xy-plane in the Mold Coordinate System to the z-axis in the same system. H.Dev (0 to 360 degrees) is the angle in the xy-plane of the Mold Coordinate System from the x-axis in the same system. Z.Dev (0 to 360 degrees) is the angle of the component around its own axis. (Relevant for components that are not bodies of revolution) Resets the parameter to its default angles. Face Offset: Type the value, or use the arrows to change the value. Click on this button to edit the component attributes. The default data is the user properties defined in the Part File properties in the Summery Information Custom dialog box. Press to close this dialogue box. to
Correct any of the previously defined steps or press the Create button
integrate the component or press the Create and New button to integrate the component and remain in the menu retaining the relevant parameters for the next component.
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5
5 Add Slides
Slides (similarly to inserts refer to Add User Part) can be added either before creation of the mold, in which case they will be taken into account during the new mold creation process, or after mold creation. Slides are SolidWorks assemblies with or without configurations. Each configuration should contain a part suffixed by _T (the same as inserts and user components), which will be used as the cutting tool for the particular configuration of the slide. MoldWorks includes as a default some standard slides from different catalogues, however, you may prepare your own slide libraries, and they can be included in the standard slide dialogue.
5-1
Add Slides
5.1
Slide
To add a slide, activate the MoldWorks > Add Slides menu or relevant icon. The behavior of this dialogue depends on whether an active mold already exists.
This is the controlling dialogue box that guides you through the steps to create a slide, while allowing you at any stage to modify previous data without having to restart.
Accesses the User Slide Library dialogue box. Accesses the Import Slide dialogue box. Accesses the Start Face dialogue box to pick the face on which to place the component(s). Accesses the Slide Positioning dialogue box. Accesses the Cam Pin Length dialogue box.
5-2
Add Slides
User Slide Library
Click on the to display only the slides for a chosen library (and expand the dialogue).
to
This dialogue is used to choose a slide and/or define new slide library folders (see next section). The default slide library folders are under the {MoldWorks}\Slides folder and appear with a lock next to them to show that they are protected. System or default libraries are placed here to protect them from accidental removal. The slide library folders will exist for subsequent sessions of MoldWorks. You can delete a folder from the folder list by selecting it and pressing the delete button.
Select a slide and press the Import User Slides dialogue.
or click twice on the slide to access
5-3
Add Slides Define a new user slide library Click on the icon to add folders to the slide library palette.
Choose a folder with user slides as defined in the previous section, and click OK to add it to the user slide library. The new folder will now appear in the left hand window of the User Slides Library dialogue.
5-4
Add Slides
Import User Slides
MoldWorks automatically reads in the slide, displays it in the window and shows its configurations in the Select configuration list box. Select Configurations Select a configuration from the Select Configuration list box. Press to close this dialogue box and move to the next step.
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Add Slides
Start Face
Select the starting face on which the slide is placed. The slide is mated to the specific face according to RefPlane (a specific plane defined in the slide definition refer to the section Preparing a user-defined slide). Press to close this dialogue box and move to the next step.
The slide will now be previewed according to the selected face. Slide Position
This dialogue allows you to translate and rotate the slide on the selected plane. Press to close this dialogue box and move to the next step.
5-6
Add Slides Cam Pin Length
This dialogue defines the cam pin length or stroke according to the Cam Pin Preview. Ref. Plane1 the reference plane for the end of the pin, usually the top face of Plate2 (cavity plate). Ref. Plane0 the reference plane from where the cam pin penetrates into the slide. Stroke the distance that the slide moves. L Length of the guide pin (only if a mold already exists). Accesses the help scheme for this dialogue. When the slide is defined before the mold has been created, then only the Stroke parameter can be adjusted. Ref. Plane1 is then automatically calculated during the new mold process as being the top face of Plate2, and the length (L) of the guide pin is adjusted according to the Stroke and length of the hole.
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Add Slides
5.2
Preparing a user-defined slide
In order to create a user-defined slide the first step is to create a SolidWorks assembly that represents the slide. The reference coordinate system of the slide is the SolidWorks coordinate system at the assembly origin. Create a plane by the name of RefPlane that indicates the plane of reference for the slide. This plane will be mated to the face selected when adding the slide to the mold. Create a plane by the name of CP_RefPlane_0 that indicates the starting plane of the cam pin penetration into the slide. The Top plane of the slide assembly will coincide with the mold parting plane as defined by the Mold Coordinate System. Create a set of configurations to represent the different sizes of the slide using the Insert > New Design Table menu (see SolidWorks Users Guide). You should also prepare a pocketing tool corresponding to the slide. This tool must also be a SolidWorks part within the slide assembly and prefixed by _T. Check one of the standard slides supplied with the installation to see in more detail how to design your own slides.
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6
6 Add Lifters
The add lifter menu is similar to the Add Slides, however; only standard lifters are allowed.
6-1
Add Lifters
6.1
Lifter
To add a lifter, activate the MoldWorks > Add Lifters menu or relevant icon. This dialogue is active only if an active mold exists. Only Lifters supplied through MoldWorks catalogue information can be used i.e. the user cannot create his own lifters.
This is the controlling dialogue box that guides you through the steps to create a lifter, while allowing you at any stage to modify previous data without having to restart.
Accesses the Lifters Library dialogue box. Accesses the Import Lifter Configuration dialogue box. Accesses the Start Face dialogue box to pick the face on which to place the component(s). Accesses the Lifter Positioning dialogue box. Accesses the Lifter Stroke dialogue box.
6-2
Add Lifters
Lifter Library
to display only the lifters for a chosen library (and Click on the expand the dialogue). This dialogue is used to choose a lifter.
to
The default lifter library folders are under the {MoldWorks}\lifters folder and appear with a lock next to them to show that they are protected.
6-3
Add Lifters Import Lifters
MoldWorks automatically reads in the lifter, displays it in the window and shows its configurations in the Select configuration list box. Select Configurations Select a configuration from the Select Configuration list box. Press to close this dialogue box and move to the next step.
6-4
Add Lifters
Start Face
Select the starting face on which the lifter is placed. The lifter is mated to the specific face. This face is actually determined according to the lifter manufacturers recommendations and should not be modified by the user.
Press
The slide will now be previewed according to the selected face.
6-5
Add Lifters
Lifter Position
This dialogue allows you to translate and rotate the slide on the selected plane (DX, DY, Rotate). Angle is the angle of the lifter and can be keyed-in scrolled or automatically calculated by clicking on the angle button and selecting an edge the result is calculated as the angle between the edge and the positive pull direction. Press to close this dialogue box and move to the next step.
6-6
Add Lifters Lifter Stroke This dialogue defines the lifter length or stroke according to the Lifter Preview.
Stroke the distance that the lifter moves. Again instead of keying-in or scrolling, click on button and select an the edge (must be less then the travel distance).
Min/Max Movement: informative information only H1/H2: clearance hole height. Travel: Distance along which the lifter can travel. Max Travel: Maximum travel distance (according to the catalogue data) Accesses the help scheme for this dialogue.
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7
7 Heat Exchange
Heat Exchange is the environment under which cooling cycle(s) are created and modified through 2d and 3d sketches. A new cycle is created through the MoldWorks > Heat Exchange > Insert Cycle menu or relevant icon or through the Insert Cycle menu activated by clicking the RHM button on Heat Exchange in the MoldWorks FeatureManager tree. At least one standard SolidWorks sketch of the cooling system should exist before entering this menu. The Heat Exchange user interface allows you the following capabilities: Dynamic Updating Once a sketch (or sketches) has been identified MoldWorks creates a dynamic preview of the cooling system including pipes according to a default diameter and extension, components (i.e. plugs, connectors, baffles and orings) taking into account extension types for internal pipe sections and orings for breaks between different mold parts. The dynamic preview also indicates collisions. Capabilities The cycle tab then allows you to browse through the pipes one by one and modify each pipe according to your requirements, including selection of component types, modification of extension direction, diameters and extensions from any of the licensed catalogues. Modification The pipes and components per cycle created will appear under the MoldWorks FeatureManager tree and can be modified with relevant RHM button menus at the cycle, pipe and component levels. Settings Default settings for the pipe diameter and extension are defined under the Settings menu by clicking the RHM button on the Heat Exchange folder under the MoldWorks FeatureManager tree. The geometry for the heat exchange components is created in the SolidWorks FeatureManager tree under Cooling Cycle_nn folders.
Heat Exchange
7.1
Insert Cycle
The Heat Exchange PropertyManager is displayed when you insert a new cycle. Two tabs appear: Positions (default). Locate the position sketch(s) and define previewing parameters of the cycle. Cycle. An interactive environment to browse through the pipe definitions, modifying diameters, components and extension types.
The current pipe segment and current component are previewed in green, while the pipes that are in collision with a component are displayed in red.
7-2
Heat Exchange
7.2
Positions
Selected Sketches Select or pre-select any 2D or 3D sketches along which the pipe cycle will be defined. Preview Cycle This option allows preview of the complete cycle (default), or the current pipe (section).
7-3
Heat Exchange
7.3
Cycle
This tab contains the heart of the Heat Exchange environment which allows you to preview the cycle including the pipes and components automatically created. The arrows are used to browse through the cycle from pipe to pipe modifying if necessary the pipe extension direction (toggle the middle button), the pipe diameter and extension and the component types and sizes accordingly and by the chosen catalogue. Any pipe in collision with a component will be highlighted in red. The Cycle tab contains the following sections: Cycle Pipe(s) Components Additional Parameter(s) (when relevant)
7-4
Heat Exchange
7.3.1 Cycle Pipe(s)

Pipe Segment. Select pipe segment. Browse through the pipe segments of the cycle.
Next. Previous. Toggle through possible extension directions (either or both sides).This button only becomes active when more then one pipe extension direction is possible. Diameter. Reflects the diameter as set in the Settings dialogue, and can be set for the current pipe segment. By Component. Marking this check box will set the pipe diameter according to the thread diameter of the component. Pipe extension. Reflects the extension as set in the Settings dialogue, and can be set for the current pipe segment.
7-5
Heat Exchange
7.3.2 Components
Set the component for the current pipe. Use the Next component button for pipes which penetrate through the mold part.
Connector
Plug
O-ring
Baffle Catalogue(s). Select the catalogue, defaults to the initial mold catalogue. Thread Standard. Depends on the component and catalogue. Type. According to the catalogue. Thread size. Select thread size, only sizes compatible with the pipe diameter will be available. Catalogue number. Alternative method of selection (especially useful when multiple thread sizes are not unique). Face offset. Offset from the part face. With component. Uncheck this parameter to clear the component for the current side of this pipe. By default every pipe penetration has a component defined (default setting is plug in most cases). Next component. Toggle this button to the other components connected to the current pipe. (Only appears if pipe is through). In order to add extra components use the Add Component menu on the RHM on the pipe segment under the relevant cycle in the MoldWorks Property after the cycle has been created.
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Heat Exchange
7.3.3 Additional Parameter(s)

This dialogue is displayed when additional parameters are relevant. Sinkhole diameter. Give the diameter of the sink hole (for connectors). Orientation. Rotate the baffle direction, or elbow connector.
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Heat Exchange
7.4
Modification
The modification menus for the pipe cycle are available through the MoldWorks FeatureManager tree by clicking on the RHM button on the relevant folder under Heat Exchange. For each Cycle the following menus are available: Edit Cycle... Preview of the cycle before its creation. Delete. Deletes the whole cycle. Hide/Show Components. Toggles the display of the components for this cycle. Rename. Rename the cycle. Add Component You can add a component to the pipe. Edit Pipe Modify pipe diameter or extension. Edit Sketch. This edits the complete sketch from which this pipe segment was created and dynamically previews the pipes on all changes (including addition of points and lines) which are made. After the process is completed the Edit Cycle PropertyManager is automatically opened. Delete. Deletes this pipe. Edit Component Modify the selected component. Delete. Deletes the component. Zoom To. Zoom to the component.
For each Pipe:
For Each Component:
7-8
Heat Exchange
7.4.1 Edit Cycle

Editing the cycle creates a preview of the cycle as it was just before the creation of the previous cycle. The Edit Cycle Property Manager appears with the current pipe parameters and is identical to the Cycle tab in the Insert Cycle PropertyManager dialogue.
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Heat Exchange
7.4.2 Add Component

This menu adds a component to the pipe segment selected. The Add Component(s) Property Manager appears with the following parameters:
Connector
Plug
O-ring
Baffle Catalogue(s). Select the catalogue, defaults to the initial mold catalogue. Thread Standard. Depends on the component and catalogue. Type. According to the catalogue. Thread size. Select thread size, only sizes compatible with the pipe diameter will be available. Catalogue number. Alternative method of selection (especially useful when multiple thread sizes are not unique. Face offset. Offset from the part face. Additional Parameter(s) Sinkhole diameter. Give the diameter of the sink hole (for connectors). Orientation. Rotate the baffle direction, or elbow connector.
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Heat Exchange
7.4.3 Edit Pipe

The Edit Pipe PropertyManager appears with the following parameters: Diameter. Modify the pipe diameter. Extension. Modify the pipe extension.
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Heat Exchange
7.4.4 Edit Component

Modification of a component essentially has the same parameters as the Add Component Property Manager.
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Heat Exchange
7.5
Settings
Select the menu MoldWorks > Heat Exchange > Settings menu or relevant icon or through the Settings menu activated by clicking the RHM button on Heat Exchange in the MoldWorks FeatureManager. The following Settings PropertyManager appears with the following sections: Pipe defaults Diameter. Set a new default diameter for subsequent pipe cycles. Pipe extension. Set a new default extension for subsequent pipe cycles.
Component(s)
Connector
Plug
O-ring
Baffle Choose a default component. The system default is a plug for part boundaries and o-rings for pipes which penetrate from one part to another. Catalogue(s): Set the default catalogue (defaults to the Default Catalogue in the General tab under the MoldWorks > Utilities > Options) Thread standard: Set the default thread standard for the selected catalogue.
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8
8 Runners & Gates
Runners & Gates is the environment under which runner systems and gates are created and modified. A new runner system is created through the MoldWorks > Runners & Gates > Insert Runner System menu or relevant icon or through the Insert Runner System menu activated by clicking the RHM button on Runners & Gates in the MoldWorks FeatureManager tree. At least one standard SolidWorks sketch of the runner system should exist before entering this menu. A new gate is created using the MoldWorks > Runners & Gates > Insert Gate(s) menu or relevant icon or through the Insert Gate(s) menu activated by clicking the RHM button on Runners & Gates in the MoldWorks FeatureManager tree. Insert Runner System - Dynamic Updating Once a sketch (or sketches) has been identified MoldWorks creates a dynamic preview of the runners including tunnels according to default parameters (as defined by the Settings menu) including the runner shape, dimensions according to the shape, orientations and angles. - Capabilities The Parameters tab then allows you to browse through the Runners by Sketch, Path or Segment one by one and modify each Runner according to your requirements to the shape and the relevant parameters for that shape. - Modification The Runners per Runner System created will appear under the MoldWorks FeatureManager tree and can be modified with relevant RHM button menus at the Runner System or Runner level.
8-1
Runner & Gates
Gates Gates can be created either at the end points of a runner or by selecting a face. The behavior of the menu is dependent on the method of creation: - For Gates created at a runner end point, the gate diameter (or width) is automatically defined as the runner diameter and direction defined by the runner segment. The system will automatically create the gate from the runner end point up to the first surface in this direction. The gate will appear under the relevant runner folder. - Gates created by face selection are defined normal to the face from the point selected which serves as the end point of the gate. The gate itself will be previewed from within the material towards the selected point and the part will become transparent. The gate type can be changed and the parameters modified accordingly. A triad is created at the point of gate creation and can be used to translate the gate along its axis, vertically or horizontally. - Modification The Gates created will appear under the relevant sub-runner if created from a runner sketch or under an Empty Runner System in the MoldWorks FeatureManager tree and can be modified with relevant RHM button menus on the specific gate icon.
Settings Default settings for the runner dimensions and Gate types and dimensions are defined under the Settings menu by clicking the RHM button on the Runners & Gates folder under the MoldWorks FeatureManager tree.
The geometry of the runners and gates is created under a folder within the SolidWorks Feature Tree and the actual tunnels are created using the Cavity function.
8-2
Runner & Gates
8.1
Insert Runner System
The Runners & Gates PropertyManager is displayed when you insert a new runner system. Two tabs appear: Sketch(s) (default). Locate the position sketch(s) and define previewing parameters of the runner system. Parameters. An interactive environment to browse through the runner shapes by sketch, path or segment, selecting the relevant shape and modifying the parameters accordingly.
The current runner(s) (depending on the browse type) are previewed in green.
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Runner & Gates
8.1.1 Positions
Selected sketch(s) Select or pre-select any 2D or 3D sketches to define the runner system. Preview system This option allows preview of the complete runner system (default), or the current runner(s) depending on the Browse type: on the Parameters page.
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Runner & Gates
8.1.2 Parameters
This tab contains the heart of the Runners System environment which allows you to preview the runners according to the browse type. The arrows are used to browse through the runner system by sketch, path or segment and modifying the technological information accordingly. This allows you to make modifications of the complete runner system (selecting By sketch as the browse type) or by the different paths (By path) or segment by segment (By segment). A hierarchy is defined (segment path sketch) where specific segment modifications can only be modified at the segment level and specific path modifications cannot be modified at the sketch level. System Runner(s) Section Runner Types Round Modified Trapezoid Trapezoid
By default the system selects the round runner type. The parameters which are displayed depend on which runner type has been selected. - Browse type allows you to define parameters at any level By segment, By path or By sketch. Depending on the choice a parameter box opens with either the current segment or the segments belonging to the current path or the sketch. This parameter box decides the scope of the choices you make throughout this dialogue.
These arrows can be used to browse through the segments, paths or the sketches. You can also select the segment from the screen.
Runner & Gates - Parameters (depending on the runner type) Round Diameter: of the runner. Sink extension: length of the extension at the corner of a path (defaults to the diameter of the tunnel). Depth: D parameter (the diameter of the enclosed circle for the Modified Trapezoid). Angle: A parameter Width: W parameter Sink extension: length of the extension at the corner of a path. Orientation angle: This allows us to orientate the runner on the correct face, spin box increments 90 degress.
Modified Trapezoid/Trapezoid -
The affect of these parameters is dependent on the scope of the browse. End Conditions Section
This will create rounded caps at the end points of the current scope. If the browse type is segment then the current segment will get the rounded cap, if the browse type is path, then only the first and last point of the path will be rounded. Round at start point creates a rounded end to the first point of the segment or path. Round at end point creates a rounded end to the last point of the segment or path. Round at all free points (for By sketch only) creates a rounded end at all
Runner & Gates free points. Optional Parameters Section (for Trapezoid type only) Type: None Fillet: Enter the radius Chamfer: Enter distance and angle.
8-7
Runner & Gates
8.2
Insert Gate(s)
If this menu is activated through MoldWorks > Runners & Gates > Insert Gate(s) or from a runner which does not have a free end point then the menu will open without a Position Point, otherwise it will pre-select the end point. This dialogue has three sections: Position Gate(s) Placement
Position section Position point/face: Select a point or a face if not pre-selected. There are 2 cases: Case 1: Point is end point of a runner: Create a cone with diameter of the runner diameter. Find the cavity surface in the direction of the segment.
If no surface is found then a warning is issued to change the angle of deviation (either V or H). If the diameter of the cone to reach the surface is > then the runner diameter a warning is issued. If instead of a cone the user selects and edge or fan gate, a similar algorithm is calculated. Case 2: Point is not end point of a runner: In this case a gate of default length is created ending at the selected point with direction from within the part. The part is made transparent. End point/face: Selecting this point will direct the gate according to the vector joining the Position Point and this point. Through end Makes sure the gate completely penetrates the face (default). This parameter is useful for submarine gates. Unmarking this will create a crescent shape hole i.e. only half the cone will penetrate the surface.
Runner & Gates Show coordinate system Shows the coordinate system on the point selected and allows you to move the gate according to the triad The next two menus are available only if the submarine gate is selected (default). Vertical deviation: Rotate the gate in the vertical direction i.e. in the plane of the gate. Horizontal deviation: Rotate the gate in the horizontal direction i.e. orthogonal to the plane of the gate. Gate(s) section Gate Types Submarine Fan Edge
By default the system selects the submarine gate. The parameters which are displayed depend on which gate type has been selected. Submarine Gate Penetration diameter (default = 0) is the diameter of the cone as it penetrates the part face (by default the diameter of the base of the cone is the runner diameter). Angle is the cone angle (not to be confused with vertical and horizontal deviation). Horizontal length of the gate is not the length of the cone axis. Penetration area: informative information.
Runner & Gates Penetration height: informative information. Edge Gate Width: at the bottom of the gate (defaults to the runner diameter). Thickness: is the height of the gate (defaults to the thickness). Side angle: allows creation of a parallelogram instead of a rectangle from top view. Bottom angle: allows creation of a parallelogram instead of a rectangle from side view. Horizontal length: is the length of the gate. Penetration area: informative information. Flip direction allows the gate to be flipped around the plane on which it was created. This is useful since usually the runner sketches are on part faces and the edge gate is parallel to this face. Fan Gate Similar to the edge gate, however it is created with a constant cross section area along its axis, with the top face always parallel to the (runner) plane. Width(1): is the width parallel to the plane at the start of the gate shape (defaults to the runner diameter). Thickness(1): is the height of the gate shape at the start. Width(2): is the width of the gate at penetration (or end point). It is dependent on the Angle in order to keep the area constant. Thickness(2): is the height of the gate shape at penetration (or end point). This is informative only as it is calculated according to the fan angle so that the cross section area is constant. Angle is the fan angle. It is dependent on Thickness(2) in order to keep the area constant. Horizontal length: is the length of the gate. Penetration area: informative information. Flip direction allows the gate to be flipped around the plane on which it was created. This is useful since usually the runner sketches are on part faces and the edge gate is parallel to this face.
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Runner & Gates Placement Delta x: move the gate in the triad x direction. Delta y: move the gate in the triad y direction. Delta z: move the gate in the triad z direction. You can also use the triads axis to move the gates graphically. Important: There are two scenarios for the gate to penetrate the cavity exist: - The gate penetrates the surface for the default cone angle, and a base of < the runner diameter. In this case we give a Penetration diameter = 0. In this case increase the Penetration diameter: till reaching the desired Penetration area. (You can also decrease the cone angle to keep the base diameter < the runner diameter). - The gate reaches the surface for a base diameter > runner diameter. A warning is given. In this case either the runner should be enlarged or the cone angle decreased until a satisfactory penetration diameter is achieved.
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Runner & Gates
8.3
Modification
The modification menus for Runners & Gates are available through the MoldWorks FeatureManager tree by clicking on the RHM button on the relevant folder under Runners & Gates. For each Runner System the following menus are available: Edit System... Preview and modify of the runner system as it was before previous creation. Check Insert Runner System for the relevant parameters. Delete System... Deletes the runner system. Rename System Renames the runner system. Add Gate pre-selects the runner free point (if exists) and opens the Insert Gate(s) menu. Edit Runner Preview and modify of the runner as it was before previous creation. Edit Sketch This edits the complete sketch from which this runner was created and dynamically previews the runners on all changes (including addition of points and lines) which are made. After the process is completed the Insert Runner System property manager is automatically opened. Delete Runner Deletes this runner. Edit Gate Preview and modify of the gate as it was before previous creation. Delete Gate. Deletes the gate. Zoom To. Zoom to the gate.
For each Runner:
For Each Gate:
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Runner & Gates
8.3.1 Edit System

Editing the runner system creates a preview of the system as it was just before the creation of the previous system. The Insert Runner property manager page appears with the current system parameters.
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Runner & Gates
8.3.2 Edit Runner

The parameters are similar to the parameters of the Insert Runner System dialogue. System Runner(s) Section The parameters which are displayed depend on which runner type has been selected. Round Diameter: of the runner. Start Sink extension: length of the extension at start of the runner. - End Sink extension: length of the extension at the end of the runner. Modified Trapezoid/Trapezoid Depth: D parameter (the diameter of the enclosed circle for the Modified Trapezoid). Angle: A parameter Width: W parameter Start Sink extension: length of the extension at start of the runner. End Sink extension: length of the extension at the end of the runner. Orientation angle: This allows us to orientate the runner on the correct face, spin box increments 90 degress.
End Conditions Section Round start edge creates a rounded end to the first point of the segment or path. Round end edge creates a rounded end to the last point of the segment or path. This will create rounded caps at the end points of the current scope. If the browse type is segment then the current segment will get the rounded cap, if the browse type is path, then only the first and last point of the path will be rounded.
Runner & Gates
8.3.3 Add Gate

This menu adds a gate to the runner segment selected. It pre-selects the free end point if it exists otherwise it is the same as using Insert Gate(s) property page.
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Runner & Gates
8.4
Settings
Select the menu MoldWorks > Runners & Gates > Settings menu or relevant icon or through the Settings menu activated by clicking the RHM button on Runners & Gates in the MoldWorks FeatureManager. The following Settings PropertyManager appears with the following sections: Runners Diameter: Set a new default diameter for runner diameters. English units: defaults to .25 inch Metric units: defaults to 5 mm. English units: defaults to .05inch Metric units: defaults to 1 mm.
Diameter increments:
Angle: defaults to 10 degrees. Angle increments: defaults to 1 degree. Gates For each gate type the system offers parameter and spin box increment defaults. Submarine gate Length: Set for gates created from surfaces (not from a runner). English units: defaults to .2 inch Metric units: defaults to 5 mm English units: defaults to .01 inch Metric units: defaults to .2 mm
Length Increments:
Cone Angle: defaults to 20 degrees Cone Angle increments: defaults to 1 degree.
8-16
Runner & Gates Fan gate Width: English Units: .1 inch Metric Units: 2 mm English Units: .01 inch Metric Units: .2 mm English units: defaults to .2 inch Metric units: defaults to 5 mm English units: defaults to .01 inch Metric units: defaults to .2 mm
Width increments:
Length: Set for gates created from surfaces (not from a runner).
Length Increments:
Fan angle: 20 degrees Angle increments: 5 degrees
8-17
Runner & Gates Edge gate Width: English Units: .1 inch Metric Units: 2 mm English Units: .01 inch Metric Units: .2 mm English units: defaults to .2 inch Metric units: defaults to 5 mm English units: defaults to .01 inch Metric units: defaults to .2 mm
Width increments:
Length: Set for gates created from surfaces (not from a runner).
Length Increments:
Side angle: 0 degrees Bottom angle: 0 degrees Angle increments: 5 degrees
8-18
9
9 Add Component
In this chapter we will describe the different standard catalogued components, which can be added using the MoldWorks > Add Component menu or relevant icon. The components are added using the same method, in a set number of steps, which, are described in the next few pages. Following are the standard components supported today by MoldWorks Release 2 grouped under the following headers: Note: Components, which are not yet supported by MoldWorks can be created and used through the User Component menu. R&B will supply from time to time catalogue libraries on the web site; including components, which have been requested and are not in the standard catalogues yet. Guide Pins Guide Pin Guide Pin2 Leader Pin Leader Pin2 Bushing Sleeve Angular Pin (inch only catalogues)
Screws Cap Screw Countersunk Screw Shoulder Screw Set Screw
Ejectors include Ejector Locks and Ejector Trimming Ejector

Add Component Ejector Pin Ejector Sleeve Flat Ejector Ejector Locks Ejector Trim
Spacers Stop Pin Stop Disc
Injection Spru Bushing Locating Ring
General Support Pillar Dowel pins Dowel Pin Tubular Dowel Pin
Holes Lifting Hole Interlocks Tapered Interlock Male Tapered Interlock Female Shoulder Plate 1 Shoulder Plate 2
Valves Air Valve Springs Spring

Add Component Stamps Date Year Date Shift Day Date Week Date
Cooling Cooling Type 1 Cooling Type 2 Cooling Type 3 O-Ring1 O-Ring2
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Add Component
9.1
Steps to add a component
When a component is added all the plates and inserts through which it fits are cut and the holes/slots are created with an oversize value. Different components are added to the mold using the same methodology. Click on the MoldWorks > Add Component menu or relevant icon The main Add Component dialogue box and the first step dialogue box Component Library are displayed: Access Component Library dialogue box. Access Start Face dialogue box. Access Positioning dialogue box. Access Component Parameters dialogue box. The main Add Component dialogue box guides you through these steps in a logical button manner (just press the at the bottom of each dialogue box), however the steps can be performed in any order, on condition that enough data is available. Before the final validation, any of the step dialogue boxes can be accessed and their parameters modified.
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Add Component
Component Library 1. First we choose the component we wish to add from the Component Library. Choose the component group by using the scroll arrows to access all the groups and then pick the relevant component.
to close this dialogue box Press and move to the next step.
Start Face 2. Then we define the starting face of the component(s) by selecting a face on a Plate or Insert. The component(s) is fixed to the specific Plate/Insert and subsequent modifications to the Plate or Insert will affect the component(s). This is the face on which the positioning sketch (defined in the next step) is projected. For ejectors this is automatically defined as bottom face of Plate 6. (It can be modified)
Press to close this dialogue box and move to the next step.
Add Component
Positioning 3. Next we select or create a sketch, which is used to define the positioning of the component. (The sketch can include points, circles and polygonal lines. MoldWorks extracts only the point data, which is the end points of lines or center points of circles). It will be automatically projected to the Start Face defined previously. The sketch can be created at this stage and does not have to be prepared before hand. If created on the fly, then it will be automatically registered into the Select sketch list box on closure.
Press to check how many points from the sketch will be used to position the component (Optional). When is pressed (default) then the components will be added to all the instances (if exist) of the parts through which the component penetrates (usually the inserts).
Press
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Add Component
Parameters 4. Finally we modify the parameters of the chosen component. Here is an example of the Cap Screw parameters dialogue box: This icon allows you to modify the catalogue from which you choose the component. It defaults to the catalogue from which you built the initial mold base. The same as on the New Mold dialogue box. You can also access the standard component user defined catalogue through this icon. Refer to Chapter 10 on how to create standard user defined catalogues.
Press this icon to add new standard component user catalogues.
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Add Component
Select the folder in which the BIN file exists (the file has the same name as the folder). This catalogue now becomes part of the standard system and will be available whenever a standard component is created.
9-8
Add Component Type: controls the component type. Press this button to activate and deactivate the component parameter scheme. Catalogue: choose the component through its catalogue number. The Parameters tab groups all the parameters for the specific component. See the parameter scheme for the meaning of each value. Use the arrows (when available) on the right of a value to scroll through the standard values for this parameter. This value is also the leading dimension for the component. It is prefixed by a * on the parameter scheme. Each leading dimension has a set of dimensions automatically defined for each catalogue. Scrolling through the leading dimension will also scroll through the set of standard dimensions, while updating the Catalogue: parameter from the previous group. The scroll bar to the right of the Parameters box is used to access the complete set of the parameters, in case there are more than five. The Oversize tab groups the oversize dimensions. See the detailed description below. S1: (depends on the specific component) controls the length of the component. Point and click in the graphic area and press this icon. The length as measured from the Plate/Insert face to the point (in the direction of the component) will be recorded in the S1 box. For Cap Screws and Countersunk screws pointing in the final part through which the screw penetrates will automatically create a standard screw with length according to the screw rules (ref Component Rule Implementation).
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Add Component
Press
to see the component parameter scheme.
Ref is the part of the component positioned on the selected face.
The Oversize tab includes those parameters for which oversize values exist. The default oversize values are determined according to the specific catalogue. Each parameter (length) can have a different oversize for each plate through which it penetrates from first to last. The list of the oversize values appears below the parameter. Select a value from the list and type-in a new value. Use before the selected value in the list or to place it after.
to place the value
The arrows jump to the column of the active oversize parameter The first value is the oversize for the first plate/insert, the second value for the second plate/insert etc. If there are more plates/inserts then oversize values,
Add Component then the second last oversize value is used for the rest of the plates/inserts (the last value for the last plate/insert). If there are fewer plates/inserts then oversize values then the extra values are ignored. Allows the new definitions of the oversize value to be saved. These definitions are written to the file oversize.usr in the user folder under the MoldWorks installation. Delete this file to reactivate the default values. Orientation is used to create an angled component. The component is pushed into the hole so that it is flush with the Plate/Insert face. V.Dev ranges from 90 to 90 degrees and is the angle from the xy-plane in the Mold Coordinate System to the z-axis in the same system. H.Dev ranges from 0 to 360 degrees and is the angle in the xy-plane of the Mold Coordinate System from the x-axis in the same system. Resets the angles to their default values. Face Offset: Type the value, or use the arrows to change the value. to access the component attributes. The following dialogue box is Press displayed: This data is written into the parts Summary Info under the Custom tab to be used in the BOM. (Accessed under the File > Properties menu in a Part window) Press to create and close this dialogue box, and return to the component parameter dialogue box or to cancel.
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Add Component
button to close this dialogue box and return to the Press the Add Component dialogue box.
Correct any of the previously defined steps or press
to create the
component(s) or press to create the component(s) and remain in the menu (New) retaining the relevant parameters for the next component. Cancels the function and erase all the dialogue boxes.
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Add Component
9.2
Component Rule Implementation

button has been activated.
For specific components the validity of the parameters is checked after the In the case of a Cap or Countersunk Screw the following rules are implemented in the order that they appear: Rule 1: Is the screw thread depth (B) as long as the depth that the screw penetrates in the final Plate/Insert? If not then a new screw must be selected or the B parameter changed (although this is not recommended since this is from the standard screw definition). Rule 2: Is the depth that the screw penetrates the final mold parts (Plates/Inserts) at least 1.5 X D1 (which is the default rule and can now be changed using the MoldWorks > Options menu ref Rules Options tab) where D1 is the diameter of the screw? (This condition is checked only for screws whose initial lengths are longer then 1.5 X D1, since there are small screws that do not satisfy this condition). If not then a message box appears which allows the following options:
Automatic Fix will then change the screw offset (i.e. push the screw into the first plate) so that the screw will satisfy this rule, however, a check will also be made that after this correction Rule 1 is still satisfied. You can now change the screw rules using the MoldWorks > Options menu
Add Component Rule 3: Is the tapped hole (in the final Plate/Insert) as long as the depth that the screw penetrates? If not then a message box appears which allows the following options:
Yes (Automatic Fix) Increases the depth of tapping preparation drill and the tap length (i.e. the tapped hole) to satisfy this rule and continues to create the components. Back allows you to modify the parameters.
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Add Component
9.3
Component Naming
The naming of the components follows the following rules: 1. For shared standard components (not ejectors) Component Name [space] Catalog Number <instance > Cap Screw M10-40 <3> 2. For shared standard Ejectors Component Name [space] Catalog Number [space] Group Id <instance > Ejector RT 10-31 25 <1> 3. For Not shared standard components (ejector trim, ort, support pillar and locating ring) Component Name [ ] Catalog Number [ ] Group Id [ ] Comp Id <instance> Ejector RT 10-315 25 1 <1>
*Component Name comes from MoldWorks Options.
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Add Component
9.4
Guide Pin
to see the parameter scheme.
Create a guide pin and guide pin hole(s) through the relevant plates according to the "Oversize" values. Press
Parameters *D1 D2 K L - Diameter of the guide pin. - Diameter of the shoulder. - Shoulder length. - Part length.
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Add Component
9.5
Guide Pin2
Create a guide pin and guide pin hole(s) through the relevant plates according to the "Oversize" values. Press
Parameters *D2 D1 K N L - Diameter of lower shaft. - Diameter of the upper shaft. - Shoulder height. - Height of the lower shaft. - Part length.
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Add Component
9.6
Leader Pin
Create a leader pin and leader pin hole(s) through the relevant plates according to the "Oversize" values. Press This dialogue has the parameter Hole Type: Hole Type 1: No hole in last plate
Parameters *D2 D1 D3 K L2 t2 S1 - Thick part diameter. - Thin part diameter. - Shoulder diameter. - Shoulder length. - Length of tail. - length of hole in last plate. - Thick part length.
(i.e. Plate9 relevant only for Hole Type 2 and 3)
Add Component S2 - Thin part length.
Hole Type 3: With angled blind hole
Hole Type 2: With through hole
Hole Type 4: With straight blind hole
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Add Component
9.7
Leader Pin2
Create a leader pin and leader pin hole(s) through the relevant plates according to the "Oversize" values. Press
Parameters *D2 D1 D3 K N L - Thick part diameter. - Thin part diameter. - Shoulder diameter. - Shoulder length. - Length of lower shaft. - Total length.
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Add Component
9.8
Bushing
Create a bushing and bushing hole(s) through the relevant plates according to the "Oversize" values. Press
Parameters *D2 D1 D3 K L2 S1 - Thick part diameter. - Thin part diameter. - Shoulder diameter. - Shoulder length. - Length of tail. - Length of bushing.
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Add Component
9.9
Sleeve
Create a sleeve and sleeve hole(s) through the relevant plates according to the "Oversize" values. Press
Parameters *D2 D1 L - Sleeve outer diameter. - Sleeve inner diameter. - Length of sleeve.
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Add Component
9.10 Angular Pin

Create an angular pin with hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 D2 D3 K A N L - Pin diameter. - Pin shoulder diameter. - Pin head diameter. - Head length. - Head angle (and Pin angle). - Head + Shoulder length - Total length.
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Add Component
9.11 Cap Screw

Create a cap screw and cap screw hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters - use the scroll bar on the righthand side to access the missing parameters. *D1 D2 - Screw diameter. - Shoulder diameter.
D3 - Diameter of tapping preparation drill. K Tap - Shoulder length. - Tap length.
DP - Depth of tapping preparation drill (affects the hole only) S1 SW B - Screw length. - Size of hexagon hole. - Actual thread length.
Add Component Gap - Safety gap.
The Through Thread check box will cause the hole to be a through hole on the final part.
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Add Component
9.12 Countersunk Screw

Create a countersunk screw and countersunk screw hole(s) through the relevant plates according to the "Oversize" values.
Parameters - use the scroll bar on the righthand side to access the missing parameters. *D1 D2 D3 drill. K Tap DP - Screw diameter. - Head diameter. - Diameter of tapping preparation - Shoulder length. - Tap length. - Depth of tapping preparation - Size of hexagon hole. - Actual thread length. - Safety gap.
drill.
SW B Gap
Add Component A - Socket head angle.
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Add Component
9.13 Shoulder Screw

Create a shoulder screw and shoulder screw hole(s) through the relevant plates according to the "Oversize" values. Press scheme. This dialogue has the parameter Hole Type: Hole Type 1: Through hole to see the parameter
Parameters - use the scroll bar on the righthand side to access the missing parameters. *M - Screw diameter. d - Screw body diameter. D - Head diameter. K - Head Depth. t - Hole extension from top of head. S - Movement distance. T - Thread length. Tap - Tap depth.
Add Component
D3 Dp L SW
- Diameter of taping preparation drill. - Depth of tapping preparation drill. - Screw length. - Size of hexagon hole.
The other two types have the same parameters but the hole does not go through the top plate. Hole Type 2: Blind drill hole. Hole Type 3: Blind countersunk hole.
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Add Component
9.14 Set Screw

Create a set screw and set screw hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 D3 SW L - Screw diameter. - Hole diameter. - Key diameter. - Length.
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Add Component
9.15 Ejector
Create an ejector and ejector hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 D2 H7 K - Ejector diameter. - Shoulder diameter. - Length of H7 hole. - Shoulder length.
Length Type Length, Ort or Trim (refer to Ejector Trim) L - Ejector length (active if Length Type is Length). Click this icon to access the ejector lock dialogue (refer to Ejector Locks).
Add Component
9.16 Ejector Pin

Create an ejector pin and ejector pin hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters - use the scroll bar on the righthand side to access the missing parameters. *D1 D3 D2 A H7 - Diameter of ejector pin. - Thick diameter of ejector pin. - Shoulder diameter. - Angle of ejector pin shoulder. - Length of H7 hole.
K - Thickness of ejector pin shoulder. L2 - Length of thick part. Length Type Length, Ort or Trim (refer to Ejector Trim) L - Ejector Pin length.
Add Component
Click this icon to access the ejector lock dialogue (refer to Ejector Locks).
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Add Component
9.17 Ejector Sleeve

Create an ejector sleeve and ejector sleeve hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 B1 D2 H7 K B2 L2 A - Return pin diameter. - Inner diameter of ejector sleeve. - Shoulder diameter. - Length of H7 hole. - Shoulder height. - Inner relief of diameter hole. - Length of B1 diameter. - Angle of inner chamfer.
Length Type Length, Ort or Trim (refer to Ejector Trim) L - Ejector sleeve length.
Add Component
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Add Component
9.18 Flat Ejector

Create a flat ejector and flat ejector hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *Y *X *D1 D2 K R2 H7 - Thick width of flat head. - Thin width of flat head. - Thick diameter. - Shoulder diameter. - Shoulder height. - Radius of shoulder. - Length of H7 hole.
Length Type Length, Ort or Trim (refer to Ejector Trim) L1 L2 - Total length. - Length up to flat part.
Add Component
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Add Component
9.19 Ejector Locks

For each ejector type there is an icon to define an ejector lock. Click the icon to access the following dialogue. Lock Type There are 4 lock types, which are accessible through this drop down menu, each with its own scheme.
Rot: Use this parameter to rotate the lock around its access. Save Click on this button to save the current parameters as the new default parameters for this lock type.
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Add Component
9.20 Ejector Trim

The ejector trim parameter is found on all ejector types and allows you to trim the ejector in 3 ways. The Trim and Ort options will be relevant only if a part has the Mold Type: Core. The Mold Type is defined either when adding an insert or by changing the attributes of a part (i.e. the core plate) through the MoldWorks > Edit > Attributes Length With this option No Trim is performed, the ejector length is calculated according to the L parameter. Trim This option trims the ejector according to the insert. The ejector length is automatically calculated to penetrate through the insert. menu.
After creation the ejector is trimmed.
Ort This option calculates the ejector up to the first point of penetration through the insert. No trimming is performed.
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Add Component
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Add Component
9.21 Stop Pin

Create a stop pin and stop pin hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 - Diameter of spacer. D2 - Diameter of spacer screw (or H7 diameter). S spacer. L - Thickness of ejector plates - Spacer length.
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Add Component
9.22 Stop Disc

Create a stop disc and stop disc hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters - use the scroll bar on the righthand side to access the missing parameters. *D S M K Tap Dp tool. D3 tool. L - Diameter of stop disc. - Thickness of stop disc. - Diameter of spacer screw. - Depth of shoulder. - Tapping length of spacer screw. - Depth of tapping preparation - Diameter of tapping preparation - Spacer length.
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Add Component
9.23 Spru Bushing

Create a spru bushing and spru bushing hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters - use the scroll bar on the right-hand side to access the missing parameters. *D2 D1 - Spru bushing head diameter. - Spru bushing diameter.
D3 - Runner diameter at the nozzle contact point. A R surface. T surface. S1 S2 - Runner cone angle. - Radius of nozzle touching the - Depth of nozzle touching the - Length of Spru bushing head. - Length of Spru bushing thin part.
Add Component
9.24 Locating Ring

Create a locating ring and locating ring hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters - use the scroll bar on the righthand side to access the missing parameters. *D1 - Locating ring external diameter. D2 - Locating ring diameter on plate side. S2 - Mold plate recess. D6 - Inner cone diameter. a - Inner hole cone angle. D4 - Inner hole diameter. S4 - Inner diameter rim size. D5 - Hole diameter of Spru shoulder. S3 - Depth of Spru shoulder. c Outer chamfer angle.
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Add Component S5 Outer chamfer height.
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Add Component
9.25 Support Pillar

Create a support pillar and support pillar hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters *D1 L - Support pillar diameter. - Support pillar length.
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Add Component
9.26 Dowel Pin

Create a dowel pin and dowel pin hole(s) through the relevant plates according to the "Oversize" values. Press Type1: One side blind hole. to see the parameter scheme. This dialogue has a new parameter Hole Type:
Parameters *D - Dowel pin diameter. t1 - Dowel pinhole extension. t2 - Dowel hole extension (ref Type3:). L - Dowell pin length.
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Add Component
Type2: Countersunk holes.
Type3: Drill holes.
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Add Component
9.27 Tubular Dowel Pin

Create a tubular dowel pin and tubular dowel pin hole(s) through the relevant plates according to the "Oversize" values. Press scheme. This dialogue has a new parameter Hole Type: Type1: One side blind hole. to see the parameter
Parameters *D D2 t1 t2 L - Tubular Dowel pin diameter. - Inner dowel pin diameter. - Extension hole. - Extension hole (ref Type3:). - Tabular Dowel pin length.
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Add Component
Type2: Countersunk holes.
Type3: Drill holes.
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Add Component
9.28 Lifting Hole

Create lifting hole(s) through the relevant plates. Press parameter scheme. to see the
Parameters - use the scroll bar on the righthand side to access the missing parameters. *M Tap D3 Dp D2 K - Lifting screw diameter. - Lifting screw tap hole depth. - Preparation drill diameter. - Preparation drill depth. - Optional counter bore diameter. - Optional counter bore depth.
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Add Component
9.29 Tapered Interlock Male

Create a tapered interlock (male part) and hole(s) through the relevant plates. This component is part of the same interlock component group, which goes together. They include male and female parts of the interlock and the 2 shoulder plates. Press to see the parameter scheme.
Parameters - use the scroll bar on the right-hand side to access the missing parameters. D* D1 A M D3 Tap Dp L1 - Interlock diameter. - Cone base diameter. - Cone angle. - Screw diameter. - Tapping preparation drill diameter. - Tap depth. - Tapping preparation drill depth. - Cone height.
Add Component L - Component length
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Add Component
9.30 Tapered Interlock Female

Create a tapered interlock (female part) and hole(s) through the relevant plates. This component is part of the same interlock component group, which goes together. They include male and female parts of the interlock and the 2 shoulder plates. Press parameter scheme. to see the
Parameters - use the scroll bar on the righthand side to access the missing parameters. D* D1 A M K L3 L - Interlock diameter. - Inner shoulder diameter. - Inner shoulder angle. - Screw hole. - Inner shoulder depth. - Interlock (male) depth. - Component length.
D*, D1, A, M and L3 should be identical to the corresponding parameters from the Tapered
Add Component Interlock Male.
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Add Component
9.31 Shoulder Plate 1 (Countersunk screw head)

Create a shoulder plate and shoulder plate hole(s) through the relevant plates according to the "Oversize" values. This component is part of the same interlock component group, which goes together. They include male and female parts of the interlock and the 2 shoulder plates. Press parameter scheme. to see the
Parameters D1* D2 D3 K S - Plate diameter. - Screw head diameter. - Screw hole diameter - Cap screw hole depth. - Plate height.
D3 should be identical to the corresponding parameter (M) from the Tapered Interlocks.
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Add Component
9.32 Shoulder Plate 2 (Cap screw head)

Create a shoulder plate and shoulder plate hole(s) through the relevant plates according to the "Oversize" values. This component is part of the same interlock component group, which goes together. They include male and female parts of the interlock and the 2 shoulder plates. Press parameter scheme. to see the
Parameters D1* D3 K S - Plate diameter. - Screw hole diameter. - Countersunk screw depth. - Plate height.
D3 should be identical to the corresponding parameter (M) from the Tapered Interlocks.
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Add Component
9.33 Air Valve

Create an air valves and air valves hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters D1* D2 L1 L2 - Air Valve head diameter. - Air Valve Tail diameter. - Air Valve head Length. - Air Valve Tail Length.
In the EOC, National, PCS and PROGRESSIVE catalogues the air valves are built from only one cylinder so the D2 and L2 parameters are set to zero.
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Add Component
9.34 Spring
Create springs and spring hole(s) through the relevant plates according to the "Oversize" values. Press to see the parameter scheme.
Parameters D1* - External spring diameter. D - Internal spring diameter. L - Spring length (free). Corresponds to catalogue number. L0 - Spring length in mold (without tension) dictates actual creation length.
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Add Component
9.35 Stamps
Create a stamp and stamp hole(s) through the relevant plate. MoldWorks supports the following stamps (not all the catalogues support all the stamps):
The parameters for all of the stamps are the same. Here we give an example of the Week Date Stamp. Press to see the parameter scheme.
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Add Component
Parameters D L - Stamp diameter. - Stamp length.
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Add Component
9.36 Add Cooling

Cooling pipes are added under the same menu (icon) as the standard . The components i.e. MoldWorks > Add Component or relevant icon same method of definition is used to create the cooling pipes except for these distinct differences: 1. No component is created. 2. The cooling pipe passes through only one plate or insert. 3. The parameter dialogue boxes for cooling pipes contains an option to create a blind or through hole. The through hole will be symmetrical at both ends. Following are the cooling pipes that are implemented in MoldWorks:
Cooling Type 1 has 2 shoulders. Cooling Type 2 has one shoulder. Cooling Type 3 has no shoulders. O-Ring1 is without shoulder including o-ring. O-Ring2 has a shoulder including o-ring. icon that is to the right of the L The parameter for a blind hole is especially useful in interactively positioning the end point of the pipe. For a through hole the scroll arrows on the right hand side of the L parameter scroll through all the faces on the way (beginning with the last face and then moving to the first, second etc.) Important: The leading parameters for the cooling pipes (Cooling Type 1 and 2 ONLY) must be scrolled in order to update the other parameters, keying in the value will NOT update the other parameters.
Add Component
9.37 Cooling Type 1

Create a pipe with two shoulders through a plate or insert. Press the parameter scheme. to see
Termination type of hole. Parameters *D1 D2 K D3 T L DT
- Choose a blind or through
- Pipe diameter. - Plug diameter. - Plug length. - Extra shoulder diameter. - Shoulder length. - Pipe length. - Thread diameter.
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Add Component
9.38 Cooling Type 2

Create a pipe with one shoulder through a plate or insert. Press the parameter scheme. to see
Termination type of hole. Parameters *D1 D2 K L DT
- Pipe diameter. - Plug diameter. - Plug length. - Pipe length. - Thread diameter.
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Add Component
9.39 Cooling Type 3

Create a pipe with no shoulders through a plate or insert. Press the parameter scheme. to see
Termination type of hole. Parameters *D1 L
- Pipe diameter. - Pipe length.
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Add Component
9.40 O-Ring1
Create an O-Ring and O-Ring groove(s) through the relevant plates. Press to see the parameter scheme.
Parameters - use the scroll bar on the right-hand side to access the missing parameters. D1* D ID D2 C T - Pipe diameter. - O-Ring diameter. - Inner O-Ring diameter. - Outer O-Ring groove diameter. - Groove width. - Groove depth.
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Add Component
9.41 O-Ring2
Create an O-Ring and O-Ring groove(s) through the relevant plates. Press to see the parameter scheme.
Parameters - use the scroll bar on the right-hand side to access the missing parameters. D1* D ID D2 T - Pipe diameter. - O-Ring diameter. - Inner O-Ring diameter. - Outer O-Ring groove diameter. - Groove depth.
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10
10 Edit
After an initial mold has been created components can be modified through the following menus. Edit Component Sketch to reposition a component or group of components. Modify Parameters to modify the parameters of a group of components. Modify Attributes to change the attributes of a mold part. Delete to delete a component or group of components. These functions operate on the cooling pipe(s) as well. The Edit Component Sketch, Modify Parameters, Modify Attributes and Delete menu/icon are active only after a component or component hole have been selected, Modify Attributes is active when any mold part is selected. Recalculate is used when mold plates have been changed in order to modify components. Edit Mold Size is used to change the definition of the initial mold, and create a completely new mold, without discarding all the additional components created.
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Edit
10.1 Edit Component Sketch

This allows you to edit the positioning sketch (MOVE) as well as ADD and DELETE point. Furthermore you can DUPLICATE the sketch with the Linear Sketch Step and Repeat icon in the open sketch mode especially useful for Multi-Inserts. First select a component or component hole from the screen or from the FeatureManager design tree then activate the editing function using the MoldWorks > Edit > Edit Component Sketch menu or relevant icon The component sketch is opened and you can now modify add, delete or duplicate sketch entities. When modifying existing sketch entities the components will be MOVED so that if you have implied constraints on the components or component holes they will not be lost. On closing the sketch, MoldWorks automatically updates the component(s) and component hole(s) taking into account the new positions. .
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Edit
10.2 Modify Parameters

This function allows you to edit the parameters of a group of components. First select a component or component hole from the screen or from the FeatureManager design tree then activate the editing function using the MoldWorks > Edit > Modify Parameters menu or relevant icon. The dialogue, which appears depends whether the component is a Standard Component or a User-defined Component. Standard Component The following component parameter dialogue box is displayed. In this instance we have edited a group of Cap Screws. The parameter dialogue box is identical to the dialogue box displayed when using MoldWorks > Add Component under the Component parameters icon. Any of the parameters may be modified. (if pressed) forces The Force Rebuild icon the system to delete and recreate the component holes. This is useful when discrepancies occur between the component position and its hole i.e. if a plate has been moved. The default is off. Press and the group of components and component hole(s) will be recreated with the new parameters.
10-3
Edit User-defined Component The following dialogue box will appear. In this case we have edited an anti-rotation ejector from the user-defined library. The configuration can be modified as well as the angle of rotation. to confirm the change and the Click modified component will be created along with the modified component holes.
Note: In order to use this menu a component or component hole must be selected (otherwise the menu/icon is not active). In the case where the selection of the component hole does not give a satisfactory result use the Select Other mechanism in SolidWorks to improve the selection or select the component from the FeatureManager design tree.
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Edit
10.3 Attributes
This function allows you to edit the attributes of the mold parts. These attributes are written into the Summary Info dialogue box under the Custom tab of the mold parts. This information is available through the standard SolidWorks Property menu for parts. First select a mold part (or in the case of components and inserts you can select the pockets) from the screen or from the FeatureManager design tree then activate the editing function using the MoldWorks > Edit > Attributes menu or relevant icon. The following dialogue box is displayed:
This information can be modified. Press to save the modifications.
Refer to Chapter 10 (BOM) for further information regarding the usage of the mold part attributes in the Bill OF Material. Notes: 1. In order to use this menu a mold part (i.e. Component, Plate or Insert) must be selected (otherwise the menu/icon is not active). 2. In the case of a Plate or Insert an extra field appears, allowing you to modify the Mold Type: (Core/Cavity etc.) This is useful when the core/cavity are created directly on the plates (3/2) and we need the core attribute for the ejector trim and other functionality.
Edit
10.4 Delete
Use this menu to delete or remove mold parts from the mold base. The result depends on the type of the mold part to be deleted. Activate this function using the MoldWorks > Edit > Delete menu or relevant icon. The following dialogue box is displayed: 1. Components. If the part to be deleted is a Component, then select the component or component hole from the screen or from the FeatureManager design tree. The name will be displayed in the Components list. A list of components from the same group can be selected or press on the Select All Group button to select all the components in the group. and the group of components Press and component hole(s) will be deleted. 2. Inserts. If the part to be deleted is an Insert then the insert will be removed (i.e. disconnected) from the mold. It will not be deleted. 3. Plates. If the part to be deleted is a Plate then the system checks which components start from the plate and lists them in the Confirm Delete dialogue box. Confirming the delete of this plate will delete these components as well.
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Edit
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Edit
10.5 Recalculate
This function identifies components positions to be recalculated, automatically heals components where ever possible, and in a second step recalculates the components. It is automatically activated after plates have been added (when the create icon is activated), if components need to be recalculated. It can be manually activated through MoldWorks > Edit > Recalculate or by clicking . Component(s) to recalculate Select components or component holes or plates where components start. The components are listed, and can be deleted or added to the list box. Entire Mold List all the components in the mold.
Click OK and the Recalculate Component(s) dialogue box appears.
and are to preview The arrows the different selected components one by one. Components which have not been automatically healed will be highlighted in red. The Edit Component Parameter icon opens the component parameter dialogue box for the current component allowing you to modify it if necessary. Click to initialize the recalculate process.
Edit
10.6 Mold Size

This menu allows you to modify the mold base plate sizes and the catalogue library. Activating MoldWorks > Edit > Edit Mold Size or relevant icon will display the initial New Mold dialogue box that you used. Change any of the parameters and click Update to recomputed the mold tool. The system will automatically recalculate the new mold base with the new initial components.
When the update has finished the system will open the Recalculate Dialogue box menu. Components, which have been added after the initial mold base, and start from plates that have moved from their former position, will be listed. The user will be then able to decide which new components to modify.
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11
11 Utilities
Under this menu or icon we have grouped together functions of a more general nature. Included are the following options: Collision allowing collision checking between different components and pipes within a plate or insert. CNC Information outputs a neutral CNC file containing all the technology, positioning etc of the holes in the plates and inserts. Hide/Show Mold Components enables the user to hide or display the first component in each group. License is a utility for the authorization and transfer of MoldWorks licenses. Options is a utility allowing you to localize the names and colors of the plates and components and colors of the component holes as well as defining the default catalogue and default mold type. Injection Machine previews an injection machine. Operations Report an Excel file list of all the manufacturing processes (drill, thread, ream etc) needed to create the holes in the plates.
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Utilities
11.1 Collision
This function operates on a single plate or insert. Activate this function with the MoldWorks > Utilities > Collision menu or relevant icon. The following dialogue box appears: Part to Check Select a plate or insert by picking on the part or in the FeatureManager design tree.
Select this icon to change the color of the plate to get a better view of the collision. Safety Distance: Enter or scroll a safety distance. The distance you enter is the minimum distance allowed between components or between a component and a plate/insert face. Go Start the analysis. If no collision is detected than a message: No Collision Detected appears in the dialogue box.
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Utilities If a collision is detected than the Part (i.e. plate or insert) is opened and displayed in shading. The dialogue box now displays the following: Pressing on this will return to the mold assembly mode. Change the color of the component(s) in collision relevant only if the components in collision are shown. Cancel. When active (pressed) makes the part transparent (easier to see the collision) When active (pressed) shows the components in collision, otherwise just the collision area.
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Utilities
11.2 CNC Information

Activate this function with the MoldWorks > Utilities > CNC Information menu or relevant icon. The standard save dialogue box for windows appears allowing creation of the CNC information file. This is a neutral ASCII file, which can be used to generate a CNC application and automatically create the tool path. It has the following format: File header:
CNC Report For Assembly: Assembly Name Date: 14-9-1999
For each Plate or Insert:

Plate no. or Insert name Description Material Heat treatment Symbol Width Length Thick ness
For each Hole type:

Number of holes Hole type Hole diameter Number of technologies Face normal vector (points inwards) Compone nt direction vector
Then depending on the type of hole:

Technology symbol Hole diameter Hole depth for each technology
And
Hole number X hole center Y hole center Z hole center for each hole
Z hole center is relative to the middle of the top face of each plate or insert, and not its position in the mold base. For Inserts the Width Length and Thickness parameters are of the minimum box surrounding the insert.
11-4
Utilities TABLES TECHNOLOGY SYMBOL Symbol D S T R A C Explanation Drill hole. Sink bore. Tapping hole. Rim hole. Anti rotation slot Conic hole
HOLE TYPE Symbol BL BL2 BK BK2 RT EG EG3 LR SB SC LS SP ESLV EPIN Explanation Leader Pin Leader Pin with parameter L2 set to zero (see parameter block) Bushing. Bushing with parameter L2 set to zero (see parameter block) Ejector. Guide Pin. Angular Guide Pin. Locating Ring. Spru Bushing. Screw. Locating Sleeve. Support Pillar. Ejector sleeves. Ejector pins - 2-diameter core pin.
Utilities ES1 ES2 WP1 WP2 WP3 OR1 OR2 DP1 DP2 SC3 SC4 SC5 CCM CCF CCS1 CCS2 AV SPR DST YST SST DDST WDST Stop Pin. Stop Disc. Cooling Pipe Type 1 Cooling Pipe Type 2 Cooling Pipe Type 3 O-Ring Type 1 O-Ring Type 2 Dowel Pin Tubular Dowel Pin Lifting Hole Shoulder screw Set screw Tapered Interlock Male Tapered Interlock Female Shoulder Plate Type 1 Shoulder Plate Type 2 Air Valve Spring Date Stamp Year Date Stamp Shift Day Stamp Day Date Stamp. Week Day stamp
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Utilities
11.3 Hide/Show Mold Components

Activate the menu MoldWorks > Utilities > Hide/Show Mold Components or relevant icon. MoldWorks then displays the first component from each group (if none are displayed) or hides all the components (if they are displayed.
11-7
Utilities
11.4 2D Drawings
Activate the menu MoldWorks > Utilities > 2D Drawings or relevant icon. In the Drawing Templates list box there appears the default templates. The MoldWorks installation includes metric and inch unit template folders under MoldWorks\DrawingTemplates called inchTemplates and mmTemplates. User defined drawing templates may be created. Use the Browse button to define the folder in which the templates reside. Select a template from the Drawing Templates list box and then select a part or parts from the Feature Manager Design Tree (or the graphic screen) By default the drawings will be saved in the active folder. Use the Browse button under the Save group to define a different path for the drawings. Press OK to activate the process, which may take a few minutes.
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Utilities
11.5 User defined templates for 2D Drawings

A MoldWorks 2D drawing template is a sample drawing of a simple part (a box) including all the characteristics that should appear in the drawing: Views, hidden lines, view scales, title block details etc. Use the following steps to create a MoldWorks drawing template. 1. Create a new folder in which you would like to save your templates. 2. Open a new SolidWorks part and create a simple box with a hole. Set the dimensions of the box to the size of a typical mold part (Plate/Insert) for which you would like to use this template. Save the part to the above folder. 3. Open a new drawing. You can choose one of your existing SolidWorks drawing templates. 4. Insert the part into the views that you would like to see in your MoldWorks template drawing. 5. Open an existing mold. 6. Activate MoldWorks > 2D Drawings or relevant icon .
7. Browse to the folder in which the new template was created and press OK. You will see a bitmap of the template.
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Utilities
11.6 Options
Activate the menu MoldWorks > Utilities > Options menu or relevant icon. The options dialogue is divided into three tabs: Plate Options, Component Options, General Options, Rules Options and PDM Options. The information will be stored in the registry, and will be valid for the next created mold.
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Utilities
11.6.1 Plate Options

This is the Plate Options tab to control plate names, symbol in the Thickness section of the New Mold dialogue, color of the plates and chamfer size (0 prevents chamfer creation) plate by plate or for the entire mold.
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Utilities
11.6.2 Component Options

This is the Component Options tab, to change the names of the components and component holes, the color of the components and component holes, and the level of component detailing.
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Utilities
11.6.3 General Options

This is the General Options tab, to control the Default Catalogue, Default Mold Type and general level of component detailing (Detail All Components), which overrides the component level detailing from the Component Options tab if Yes or No. Choosing Selective will take into account the Details parameter from the Component Options tab. The User Custom Properties section allows you to add properties with/without defaults and lists separated by ;. These properties will automatically be shown when the attribute tab is activated in MoldWorks.
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Utilities
11.6.4 Rules Options

The screw rules and cosmetic thread option are used for the component screws and holes. Screw rules can be adjusted by the user. For screw rules select one of the following two options: Minimum thread engagement depth. Key-in the relation between the length of the screw in the final part and the screw diameter. Default is 1.5. or Use user defined screw hole and rule tables. Mark this parameter in order to override the Minimum thread engagement depth. Click on this button to access the EXCEL file containing the screw rules. Then after closing the Excel file. The ScrewRuleTables.xls file is situated in the ScrewTable folder under user in the MoldWorks installation. The file has a separate Worksheet for mm and for inch with a graphic help to describe the different parameters. Press OK to exit the Rules Options tab. If the Use user defined screw hole and rule tables parameter is checked and the Excel file has been modified then MoldWorks will create a new binary file of the same name (ScrewTable.bin) in the same folder. This is the file which MoldWorks uses when creating holes and/or checking screw rules. Thread on screw. Mark this parameter in order to override the B parameter in the screw dialogue and key-in the relation between the length of the thread on the screw and the screw diameter. The Cosmetic Threads section has a check box in order to create cosmetic threads on the screw holes or not. The initial default is to create the cosmetic threads.
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Utilities
11.6.5 PDM Options

All mold parts can now be prefixed or suffixed in order to allow unique naming for the mold including plates and components. Subsequent versions will allow automatic connection to PDM servers to allow standardization of components and more. Only the Browser Name section of the PDM Options tab has been realized in this version of MoldWorks. Notice: The Prefix and Suffix values are stored with the mold so that when the mold is reopened for further processing these values will be updated.
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Utilities
11.7 Injection Machine

Activate this function through the MoldWorks > Utilities > Injection Machine menu or relevant icon. It is active only when a mold already exists. The Injection Machine dialogue appears along with a preview of the Injection Machine.
The Closing and Injection Unit sections contain read-only information. The Injection Machine data is stored in an Excel file modifiable by the user.
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Utilities
11.8 Injection Machine Data

We supply an Excel template file InjectionMachine.xls to define injection machine data under the MoldWorks\InjectionMachine folder. Under the same folder there is also an InjectionMachine.bin file DO NOT MODIFY IT.
In the Excel file we have defined the machine parameters and data type for each parameter. Do not change the number of parameters (although the parameter names can be modified) In this file we have supplied some R&B machines as well as the default holes layout database as defined in EURO MAP standard. You can add your machine data to this file. Only the RED colored parameters are taken into account when building the actual injection machine for preview and MUST BE SUPPLIED. The best way to add your data would be to copy one of the existing columns and modify the data. Check the next section to see the exact file format. After a new Injection Machine data file has been created MoldWorks will translate the data to a bin format when first used in order to accelerate the performance. This translation phase can take a few minutes.
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Utilities File Format: The first two rows (i.e. Manufacturer and Size) are used to determine the specific injection machine. In the Unit row write millimeter or inch to define the machine dimension units. The next rows (until Injection rate) contain the parameter values as they define in the machine Manufacturer book i.e. in the Clamping force row (optional) write the machine Clamping force as defined in the Manufacturer book. In the Ejection hole_1 diameter row fill the diameter of the first ejection hole (hole without thread) you have in the machine. In the Ejection hole_1 X coordination row fill the X (length) coordinate of the first ejection hole. In the Ejection hole_1 Y coordination row fill the Y (width) coordinate of the first ejection hole. The X, Y coordinates should be in the positive quadrant of the coordinate system (both X and Y positive), Mold Works will duplicate holes into the other quadrants. There are twenty Ejection hole rows even if you do not use them all leave the rows empty. Next we have the Thread hole data: In the Thread hole_1 diameter row fill the diameter of the first thread hole you have in the machine. In the Thread hole_1 X coordinate row fill the X (length) coordinate of the first thread hole. In the Thread hole_1 Y coordinate row fill the Y (width) coordinate of the first thread hole.
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Utilities
11.9 Operations Report

Activate this function with the MoldWorks > Utilities > Operation Report menu or relevant icon. The standard save dialogue box for windows appears allowing creation of an Operation Report file in Excel format, which can be used to estimate the manufacturing time and control the manufacturing process. In the operation section we build a list of all the manufacturing processes (drill, thread, ream etc) needed to create the holes in the plates. For each component we build a list of the parts it cuts (plates and inserts etc.) and in each part the hole type and the dimension. The file has the following format: Operation: component name as created in the tree. Component: component catalog number including the catalog name. Quantity: quantity of components in the group. Parts Affected: list of plates and inserts that the component penetrates. Ref: reference name of the part. Type: hole type in part (drill, thread, groove etc). Condition: hole end condition (blind or through). Clearance: hole clearance type if exists (fit, normal, loose). CB Diameter: for Counter bore holes the bore diameter. CB Depth: for Counter bore holes the bore depth. Hole Diameter: hole diameter. Total Drill: total drill depth. CS Diameter: for Counter Sink holes the Sink diameter. CS Depth: for Counter Sink holes the Sink depth. CS Inclination: for Counter Sink holes the Sink Inclination. Thread Norm: thread type (M, BSP, NPT etc). Thread: for threaded hole the thread dimension.
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Utilities
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12
12 B.O.M.
MoldWorks automatically records the Bill of Material as defined by the specific catalogue used. This information by default includes: ITEM NO. QTY. PART NO. DESCRIPTION MATERIAL SYMBOL HEATTREATMENT CATALOGUENUMBER DIM1 (new) DIM2 (new) DIM3 (new) (new) DIMx (new) Vendor (new) The structure (i.e. parameters) of the BOM can be modified permanently (i.e. for all molds created) through the General tab on the Utilities > Options or for a specific part through the Custom tab on the File > Properties menu.
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B.O.M. DIM1, DIM2 and DIM3 have the following meanings: For plates and inserts they are the dimensions of the min max box (i.e. length, height and width for a regular plate). For Components we have the following table:
D1, L1 D2, S1, D1, S2 D2, S1 D2, L D1, S1 D1, S1 M, L D1, L D1, D3, L D1, B1, L X, Y, L1 D1 D D1, S2, D2, S1 D1, S1 D1, L D, ID D, ID D, L D, L D1, S D1, S D, L D, L
Guide Pin Leader Pin Bushing Sleeve Cap Screw Countersunk Screw Shoulder Screw Ejector Ejector Pin Ejector Sleeve Flat Ejector Stop Pin Stop Disk Sprue Bushing Locating Ring Support Pillar O-ring 1 O-ring 2 Tapered Interlock Mail Tapered Interlock Female Shoulder Plate 1 Shoulder Plate 1 Dowel Pin Triangular Dowel Pin
You can modify this data through the Attributes

menu or icon on the main

12-2
B.O.M. MoldWorks (ref 6.4) bar or in the Component parameter dialogue box. The information is recorded in the Summary Info box under the custom tab for each part. We have created a special Excel file MoldBom.xls in the user folder under the MoldWorks installation. You can copy this file to the SolidWorks\lang\english folder (or any other language folder), which is the default folder for the BOM in the Insert > Bill of Materials menu under Drafting. To insert the MoldWorks BOM choose the MoldBom.xls in the Insert > Bill of Materials menu under drafting. The resulting BOM will include the items as described above.
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13
13 Convert Catalogue
This utility enables users to create their own standard component catalogue definitions, through the use of the EXCEL file format, and a converter to transform the data into a binary format for efficient use within MoldWorks. Only current standard component types already existing in MoldWorks can be created. Each separate component has its own EXCEL file, and the converter will translate ALL the files into a single standard BIN library with the name of the folder in which they reside i.e. if the component EXCEL files reside in the folder favorites, a binary file named favorites.BIN will be created which holds all the component types defined within the same folder. The converter runs as a separate product external to the Interactive MoldWorks. It is accessed through Start > MoldWorks 2009 > Convert Catalogue. As an example we have supplied all the component catalogue information for the Training catalogue under the installation folder {MoldWorks 2009}\Training. In order to create your own catalogue perform the following: 1. Copy the folder Training to a new one. 2. Modify the information in the different component files (refer to section 3 for the file format definition). 3. Run the converter. icon to access 4. During the standard component definition press the the catalogue dialogue. Press the User tab and select the folder in which the new component data resides.
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Convert Catalogue
13.1 Converter
Press the Start > Programs > MoldWorks 2009 > Catalogue Converter and the following dialogue box appears:
This dialogue allows you to convert all the EXCEL catalogue files in a specific folder Press Browse and select the folder in which all the catalogue component data EXCEL files exist. Press Convert to convert the data. If there is a mistake in the data then the converter will give a feedback of the problematic file as well as the row in which the problem was found.
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Convert Catalogue
13.2 Component EXCEL file format

Here is an example of the Excel file format
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14
14 Help
MoldWorks User Guide and Tutorial are accessed directly from the general SolidWorks help menu. The Tutorial is in PDF format, and needs the Acrobat Reader (version 7.0 at least) to access. Acrobat Reader can be installed with SolidWorks or downloaded free from the web.
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MoldWorks 2009 User Guide September 2009

Coordinate System New Mold

Add Standard Plate Add User Plate

Add User Part

4.1 4.2 4.3

Preparing a user-defined slide ....................................................... 5-8

Positions ......................................................................................... 7-3

Runners & Gates

9.10 Angular Pin 9.11 Cap Screw

....................................................................... 9-23 ............................................................................ 9-24 .............................................................. 9-26 .................................................................. 9-28

9.12 Countersunk Screw 9.13 Shoulder Screw

9.14 Set Screw 9.15 Ejector 9.16 Ejector Pin

........................................................................... 9-30 .................................................................................... 9-31 ............................................................................ 9-32

9.17 Ejector Sleeve 9.18 Flat Ejector 9.19 Ejector Locks

................................................................... 9-34 ........................................................................... 9-36 ......................................................................... 9-38

9.27 Tubular Dowel Pin 9.28 Lifting Hole

.......................................................................... 9-51 ....................................................... 9-52

9.29 Tapered Interlock Male

9.30 Tapered Interlock Female

................................................. 9-54 ................... 9-56

............................................................................... 9-58 ............................................................................... 9-59 .............................................................................. 9-60

9.36 Add Cooling .................................................................................. 9-62

................................................................... 9-63 ...................................................................... 9-64 ....................................................................... 9-65

.............................................................................. 9-66 ............................................................................. 9-67

............................................................................... 10-5 .................................................................................... 10-6 ........................................................................... 10-8

10.6 Mold Size

................................................................................ 11-2 ................................................................... 11-4 ................................................ 11-7

11.2 CNC Information

11.3 Hide/Show Mold Components 11.4 2D Drawings

Chapter 12 12 B.O.M. Chapter 13 13 Convert Catalogue

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

Steps in Designing a Mold Base Using MoldWorks

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks FeatureManager Tree

MoldWorks2009 User Guide

1.8.1 Display Configuration

MoldWorks2009 User Guide

1.8.2 Heat Exchange

MoldWorks2009 User Guide

These menus are used to manage the Cooling Cycle data.

MoldWorks2009 User Guide

RHM click on a pipe segment

RHM click on a component

MoldWorks2009 User Guide

1.8.3 Runner & Gates

MoldWorks2009 User Guide

These menus are used to manage Runner System data.

MoldWorks2009 User Guide

RHM click on a Runner

RHM click on a Gate

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide

MoldWorks2009 User Guide