Giáo trình NX Mold Wizard Design Process

Phần 1. Tổng quan về khuôn & Quy trình thiết kế khuôn ép nhựa. - Kết cấu khuôn - Quy trình khuôn ép nhựa - Giao diện & Công cụ thiết kế khuôn Phần 2. Kiểm tra sản phẩm trước khi phân khuôn - Kiểm tra góc Draft của sản phẩm so với hướng phân khuôn - Kiểm tra độ dày của chi tiết Phần 3: Phân khuôn (Từng bước cho 1 sản phẩm thực tế điển hình) - Bước 1. Cài đặt các thông số ban đầu cho chi tiết - Bước 2. Cài đặt gốc tọa độ cho tất cả các thành phần của khuôn - Bước 3. Xác định hệ số co ngót - Bước 4. Tạo phôi cho quá trình tạo Cavity và Core (Workpiecs) - Bước 5. Bịt kín các lỗ hở để tạo mặt phân khuôn phụ - Bước 6. Xác định các khối nằm trong Cavity, Core và Slide - Bước 7. Tạo mặt phân khuôn chính - Bước 8. Tiến hành tách thành 2 mảnh khuôn Cavity và Core - Bước 9. Sắp xếp 2 sản phẩm trên một lòng khuôn Phần 4: Mô phỏng dòng chảy nhựa bằng Advance Eassy Fill (MOLDEX 3D) - Tạo cổng phun nhựa - Gate wizard - Thiết kế kênh dẫn nhựa - Runner wizard Phần 5: Thiết kế khuôn hoàn chỉnh - Chọn áo khuôn - Mold Base Library - Thiết kế vòng định vị - Thiết kế bạc cuống phun - Sque Bushing - Thiết kế cổng phun - Gate - Thiết kế kênh dẫn nhựa - Runner - Thiết kế Slide - Cơ cấu kéo ngang - Thiết kế Lifter: Lưỡi đẩy, chốt đẩy - Thiết kế hệ thống làm mát - Cooling Systerm Phần 6: Mô phỏng khuôn ép nhựa Phần 7: Xuất bản vẽ Drawing trong Mold wizard

Mold Wizard Design Process

1.Initializing a mold design project

Setting project defaults

Design

Intent

In this activity you use specific part naming rules to replace the default rules The naming rules specified are to familiarize you with using name rules, and apply only to a series of activities in this course that are based on the mouse project

Activity

Launch the activity

Setting project defaults

1 Create a mouse project

Choose Start All Applications Mold Wizard

On the Mold Wizard toolbar, click Initialize Project

In the Open dialog box, navigate to your parts \ initialize folder,

select mouse_case_upper, and click OK

Design Intent The original parts of the mouse are designed in inches

The design intent is to create a metric tooling assembly

In the Initialize Project dialog box, in the Project Settings group, in the Name box, clear

the default text, type mouse, and press Enter

From the Material list, select ABS

From the Configuration list, if necessary, select Mold.V1

In the Settings group, from the Project Units list, select Millimeter

Select the Rename Components check box

Click Edit Material Data Base

Note The material database is a list of materials and shrink factors

You can add materials you use to the list, and set any shrink factor to match your experience

Choosing a material is a convenient method to set a shrink factor The name of the material is not stored

When you have examined the spreadsheet data, close the spreadsheet without saving it

In the Initialize Project dialog box, click OK

In the Part Name Management dialog box, in the Part Names group, verify whether the

first part listed is mouse_top_000

Only if the numeric suffix for the top part mouse_top is not 000, do the following:

o In the Name Rules group, in the Next Part Name Number box, type 0 and press Enter

o In the Part Names group, click Set All Names

2 Examine the project structure that was just created

On the Resource bar, click the Assembly Navigator tab

Tip You can keep the navigator open by clicking the push pin button in the left corner of the Assembly Navigator title bar

The appearance of the button changes to indicate that the window is pinned in the open position

Expand nodes mouse_layout_021, mouse_prod_003, and mouse_parting-set_020 and

observe the names used

Note The original product part is never renamed

The numeric suffixes are assigned in sequence during your NX session, beginning with 0 in each new session

During this course, you are asked to reset the starting number to 0 for each new assembly you initialize This is to make the numbers you see in NX match the examples in this student guide

Choose Information Assemblies List Components

What part is represented by its Empty reference set?

The original product model, mouse_case_upper

What part has different Units?

The original product model, mouse_case_upper

Close the Information window

3 Examine the relationship between components of the product subassembly

In the Assembly Navigator, select the original product component, mouse_case_upper

In the Dependencies group, click Expand Next Level until the entire sequence of

dependent parts is revealed

Observe the order of dependency

The tree structure reflects the order in which the component bodies are WAVE linked

4 Select the Advanced with full menus role

On the Resource bar, click the Roles tab

In the System Defaults group, select the Advanced with full menus role

In the Load Role dialog box, click OK

Note This course is designed for the Advanced with full menus role

5 Save and close all parts

Related information

For more information:

 Use the Command Finder to search for Initialize Project

Choosing and setting mold coordinate systems

Design

Intent

The mouse project parts are modeled with a common coordinate system relative

to the mouse assembly, regardless of how the individual parts are molded

You must establish a suitable mold CSYS for each component

Activity

Launch the activity

Choosing and setting mold coordinate systems

1 Verify that the Mold Wizard application is running

2 From your mold_csys folder, open mold_csys_top_010

3 Reposition the product so that a section of planar face is on the XY-plane (parting plane) of the mold tooling assembly

On the Mold Wizard toolbar, click Mold CSYS

Caution It is important to click Mold CSYS before you adjust the working coordinate

system

When the Mold CSYS dialog box is open, the Mold Wizard software

compensates for the origin of the shrinkage scale feature

Right click the view background and choose Orient View Front

The orientation of the WCS is suitable for the upper case, but the origin Z level (the XC-YC plane) is not convenient for molding The XC-YC plane should be at the principal parting plane

Design

Intent

You are going to position the WCS in the same plane as the flat section at the right side of the part in the preceding figure

From the graphics area, double-click the WCS

If necessary, select the origin handle of the dynamic CSYS

On the Selection bar, if necessary, select Point on Face to turn the option on

Click to indicate a point on the lip near the mid center of the flat region as shown in the following figure

Tip Rotate the part to make it easy to select the point

The WCS is relocated to the end plane of the case:

Click the middle mouse button to end WCS dynamics

In the Mold CSYS dialog box, in the Change Product Position group, select Product Body Center

In the Lock XYZ Position group, if necessary, select the Lock Z Position check box

Click OK

Note The mouse_csys_parting-set subassembly is repositioned in

the mouse_csys_prod structure The WCS is now at the mold center, with ZC 0.0

at the main parting level

4 Verify the shrinkage factor

On the Mold Wizard toolbar, click Shrinkage

Note In the Scale Body dialog box, in the Type group, you can see that you have

a Uniform type scale feature

In the Scale Factor group, you can see that the scale in the Uniform box is

1.006 The shrinkage for this mold has already been applied by specifying a Material from the Initialize Project dialog box

5 Save and close all parts

Related information

For more information:

 Use the Command Finder to search for Mold CSYS

3.Workpiece

Edit the workpiece sketch

Design Intent In this activity you are going to design a cylindrical user-defined insert

Activity

Launch the activity

Edit the workpiece sketch

1 Initialize the hub project using the information provided below:

o First Part = /hub / hub

o Project Name = hub (default)

o Material = PC+ABS

o Configuration = Mold.V1

o Project Units = default (Inch)

o Name Rule = <PROJECT_NAME>_<TEMPLATE_NAME>_???

o Next Number = 01

o Mold CSYS = Specify later

2 Specify the mold coordinate system for the hub

On the Mold Wizard toolbar, click Mold CSYS

Double-click the WCS

Select the YC-ZC rotation handle on the plane at the base of the X-axis handle and rotate the WCS 90 degrees clockwise, so the Z-axis points along the cylinder axis in the direction

shown

Click the middle mouse button to end WCS dynamics

In the Mold CSYS dialog box, in the Change Product Position group, if necessary,

select Current WCS

Click OK

3 Redefine the workpiece to be a cylinder instead of a block

On the Mold Wizard toolbar, click Workpiece

Note The hub_layout_022 subassembly is displayed, and hub_workpiece_010 is the

work part (Numeric suffixes may vary.)

In the Workpiece dialog box, in the Dimensions group, under Define Workpiece,

click Sketch Section

When the sketch opens, press Control+A to select every object currently in the sketch

Press the Delete key

On the Sketch Tools toolbar, click Circle

Position the cursor over the datum point at the origin of the datum CSYS, as shown in the following figure

Note When the cursor is over the existing point, the indicator changes to show a point symbol, and the coordinates boxes show zero in both X and Y

When you select an existing point, by default, a coincident constraint is

automatically created

Click to select the existing datum point

Drag the circle to a diameter of about 3.25 inches

In the Diameter on-screen input box, type 3.25 and press Enter

Click the middle mouse button to close the Circle dialog bar

On the Sketch Tools toolbar, click Inferred Dimensions

Select the circle and indicate a dimension origin

Tip If you created the circle with a diameter other than 3.25, you can change the dimension to 3.25

With the circle dimensioned, the sketch is fully constrained

Click the middle mouse button to close the Dimensions dialog bar

On the Sketch toolbar, click Finish Sketch

Note The solid body is based on the extruded sketch, not the individual curves

Even with a complete new set of curves, the body updates

4 Define the extents of the workpiece cylinder

When the Workpiece dialog box reappears, in the Limits group, in the Start Distance box,

type –0.5 and press Enter

Next to the End Distance box, click the Function button and choose Make Constant

In the End Distance box, type 1.5 and press Enter

Click OK

5 Save and close all parts

Related information

For more information:

 Use the Command Finder to search for Workpiece

User defined workpiece

Launch the activity

User defined workpiece

1 With the Mold Wizard application running, from your workpiece folder,

open user_body_top_010

2 Display the parting part

On the Mold Wizard toolbar, click Mold Parting Tools

On the Mold Wizard toolbar, clear the Mold Parting Tools button to close the toolbar

3 Create a revolved body for the workpiece

Note The work layer is 2

The existing sketch is in layer 2

The Modeling application is running because the assembly was saved in the Modeling application

6 On the Selection bar, from the Curve Rule list, if necessary, select Infer Curves

7 Select any curve in the sketch, as shown in the following figure

8

9 In the Revolve dialog box, in the Axis group, click Specify Vector

10 On the Selection bar, from the Type Filter, select Datums

11 Select the Y datum axis of the Datum CSYS, as shown in the following figure

12

13 Click OK

15 Using the Part Navigator, reorder the Linked Body (2) “UM_INSERT_BOX” feature after

the new Revolve feature

16 Define the workpiece

On the Mold Wizard toolbar, click Workpiece

In the hub2_workpiece_009 part, with the Workpiece dialog box displayed, make

layer 2 Selectable

In the Workpiece dialog box, in the Workpiece Method group, from the Workpiece

Method list, select Cavity-Core

Select the user defined revolved body, as shown

Click OK

Tip You can edit the display of your user defined workpiece body

Using Edit Object Display, you can change the translucency to resemble the

default workpiece

17 Save and close all parts

Related information

For more information:

 Use the Command Finder to search for Workpiece

1 From your layout folder, open layout_top_010

Right-click the view background and choose Orient View Top

Design

Intent

The lug must face the center of the array

The lug currently lies on the –YC-axis; so, you must use the start

angle option to translate the part in the +YC direction

The arc centers of the inserts must lie on a 240 mm diameter circle, six cavities equally spaced This makes the radius 120 mm and the number of cavities 6

2 Start a circular layout

Click Cavity Layout

In the Cavity Layout dialog box, in the Layout Type group, from the list, select Circular

If necessary, select Radial

Click Specify Point

On the Selection bar, verify that Arc Center is selected

Select a circular edge of the insert

Note As you select the edge, notice that the cursor shows that you are selecting an arc center

3 Specify the circular layout parameters

In the Circular Layout Settings group, in the Cavity Count box, enter 6

In the Start Angle box, type 90, and press Enter

If necessary, in the Rotate Angle box, type 360 and press Enter

In the Radius box, type 120 and press Enter

In the Generate Layout group, click Start Layout

Fit the view to the screen

From the Edit Layout group, click Auto Center

Note This cavity layout is already centered, but clicking Auto Center stores

information that will later be used when adding a Mold Base

Click Close

4 (Optional) Click Undo to experiment with different circular array parameters

Tip Try using a different reference point A quadrant point adjacent to the lug works well

5 Save and close all parts

Related information

For more information:

 Use the Command Finder to search for Cavity Layout

You are going to locate the parting for each insert 20 mm above the bottom of the

lower core insert This leaves 30 mm as the cavity side Z dimension

Activity

Launch the activity

Family mold project — toy shapes

1 Initialize a new toys project

Design

Intent

The original parts are modeled in inches; you must be careful to specify a millimeter assembly

o First Part = / family / circle

o Project Name = toys (Notice that you are not accepting the default name.)

o Material = PS

o Configuration = Mold.V1

o Project Units = Millimeter

o Name Rule = <PROJECT_NAME>_<TEMPLATE_NAME>_???

o Next Number = 01

o Mold CSYS = Specify later

2 Load a second part

In the Open dialog box, from the list of parts, select square and click OK

In the Part Name Management dialog box, click OK to accept the default names

Open the Assembly Navigator and review the structure of the *_layout subassembly

3 Create an insert for the currently active product

Design

Intent

The two products are currently positioned at the same coordinates You are going to create the inserts for each product, and then line up the edges of the inserts as shown in the following figure:

On the Mold Wizard toolbar, click Workpiece

Tip The last product loaded always becomes the active product

Under Define Workpiece, click Sketch Section

No changes are needed to the workpiece sketch at this time

In the Workpiece dialog box, in the Dimensions group, under Limits, in the Start

Distance box, type –20 and press Enter

In the End Distance box, type 30 and press Enter

In the Workpiece dialog box, click OK

4 Define the insert dimensions for the circle part

On the Mold Wizard toolbar, click Family Mold

In the Family Mold dialog box, from the list, select circle, and click OK

Tip You can click Family Mold to confirm the currently active product

On the Mold Wizard toolbar, click Work Piece

In the Workpiece dialog box, in the Start Distance box, type –20 and press Enter

In the End Distance dialog box, type 30 and press Enter

In the Workpiece dialog box, click OK

5 Position the inserts for the circle and square products

On the Mold Wizard toolbar, click Cavity Layout

Fit the view in the window to see clearly where both inserts are located

Note The circle part and insert are highlighted It does not matter which part you move Eventually, you are going to use the Auto Center command to position

your entire layout at the mold center

In the Cavity Layout dialog box, in the Edit Layout type group, click Transform

In the Transform dialog box, in the Result group, select Move Original

In the Transformation Type group, if necessary, expand the list and select Show

Shortcuts

In the Transformation Type group, if necessary, click Translate

Move the sliders to practice repositioning an insert

Design Intent The desired translation is 175 in X and 0.0 in Y

If necessary, in the X distance box, type 175

In the Y distance box, type 0

Click OK

In the Cavity Layout dialog box, in the Edit Layout type group, click Auto Center

In the Cavity Layout dialog box, click Close

6 Save your work

Choose File Close Save All and Close

Related information

For more information:

 Use the Command Finder to search for Family Mold

Activity

Launch the activity

Edge patch and edit patch surface

1 Create a project for battery_upper

o Mold CSYS = default

Note You are using an ESI project configuration since the full mold tooling assembly

will not be used for this training activity

2 Use the Edge Patch command to patch the hole in the conical face

On the Mold Wizard toolbar, if necessary, click Mold Tools

Click Edge Patch

Note If a top level assembly is displayed when you click Edge Patch, the parting part

becomes the displayed part

In the ESI configuration, the *_ESI_Analysis part acts as the parting part

From the Type list, select Face

As you move the cursor over the graphics window, observe that only faces with interior holes are selectable

On the Selection Bar, from the Face Rule list, select Single Face

Select the interior conical face as shown below

From the Settings group, verify that As Patch Surface is selected

In the Edge Patch dialog box, click Apply

A surface is created to represent where the slide or lifter steel will shut-off against the core or cavity steel

Select the Part Navigator tab and review the Feature Group (6) “patch_set1”

Note Patch sheets are created as feature groups

The first sheet is created in the simplest geometry format possible

The first sheet is the parent for core and cavity patch sheets

The three sheets and any other related features are then added to the feature group

3 Use the Edge Patch command to patch the simple holes in the part

From the Type list, select Body

From the graphics window, select the solid body

All open loops in the selected body are highlighted

Zoom in on large circular opening and note that the highlighted loop is at the bottom of the part

Mold Wizard considers this a ―crossover‖ face To define a patch surface at the proper location to be molded, this face would need to be divided at the zero degree isocline using the Mold Tools Face Split or Mold Parting Tools commands

Design

Intent

You will ignore this opening for this portion of the activity since these type

of crossover faces can automatically be corrected using the Mold Wizard Mold Parting Tools

From the Loop List group, verify that Select Loop is highlighted

From the graphics window, hold the Shift key and deselect the loop as shown below

Click OK to create the patch surfaces

Rotate your part as needed and review the newly created patch surfaces for the mounting boss holes and slide hole

4 Delete a patch sheet

Rotate your part as needed and zoom in on the cutout patches that cross multiple faces For geometry like these cutouts, there are two possible solutions:

o The solution shown below is correct for this shut-off

o The solution shown below is incorrect for this shut-off

On the Mold Tools toolbar, click Edit Parting and Patch Surface

Hold the Shift key and deselect the incorrect patch set surface as shown (If both patch set surfaces were created correctly, then you can select either one.)

In the Edit Parting and Patch Surface dialog box, click OK to delete the patch

When you use the Edit Parting and Patch Surface command in Mold Wizard,

unseen members of feature sets are automatically deleted

5 Traverse a closed loop using Edge Patch

On the Mold Tools toolbar, click Edge Patch

If necessary, zoom in on the cutout area without a patch sheet as shown in the following figure

From the Type list, select Traverse

From the Traverse Loop group, expand the Settings group

From the Settings group, clear the Traverse by Face Color check box

Select the vertical edge shown in the following figure

From the Segments group, click Accept

Continue using a combination of Accept and Cycle Candidates until you have selected a complete closed loop as shown below:

In the Loop List group, verify that the Select Loop count is (10)

In the Loop List group, select Select Reference Face

If the faces shown in the following figure are highlighted, in the Loop List group,

click Switch Face Side

Note Four interior faces should now be highlighted as shown below (Rotate the model as needed to verify the interior faces.)

Click Apply

The patch set has three faces that match the missing geometry, as shown in the following figure

Leave the Edge Patch dialog box open

6 Patch an open loop using Edge Patch

Design

Intent

The next loop to patch has no lower boundary at the basic parting plane

so you will use a different method

Zoom in to the area illustrated in the following figure

From the Type list, select Traverse

Select the upper end of the edge shown below

Tip When you select edges or curves for a chaining operation, always select at the end at which you want the chain to continue

Note An additional edge is highlighted as the next path

From the Segments group, click Accept

Continue using Accept until you have selected loop back to basic parting line on the right side of the opening as shown below

After clicking Accept for the last vertical segment, your next path should like as shown

below:

At this point, you actually want to cross over the opening and return to the first loop edge selected

From the Segments group, click Close Loop

In the Edge Patch dialog box, click OK

In the failure dialog box, click OK

Note The software has problems dealing with edge loops where:

There are many edges and complex bounding faces

The edges represent a cut through a periodic face, such as the toroidal faces in

If necessary, start the Modeling application

Choose Insert Sweep Swept

On the Selection bar, from the Curve Rule list select Single Curve

To begin the first section string, at the end illustrated, select the edge shown

Select the second edge as shown

Note When you select edge strings for free form faces, the first click establishes the alignment of the string, represented by a vector arrow

If your vector arrow does not match the illustration below, from the Sections group,

click Reverse Direction

In the Sections group, click Add New Set

For section 2, at the same end as you selected section 1, select the edge at the right side

of the open loop as shown in the following illustration

Select the second edge for section 2

Click the middle mouse button to complete Section 2

Warning Make sure that the direction vectors are aligned, otherwise the sheet is

twisted

You can reverse the direction of either section string by selecting it in the list, and clicking Reverse Direction

In the Guides group, click Select Curve

Tip You can collapse the Sections group if it is necessary to fit the dialog box in the

available screen space

If necessary, on the Selection bar, from the Curve Rule list, select Single Curve

Select the edge at the end shown