Catia - Mold Tooling Design

CATIA Training

Mold Tooling DesignMold Tooling DesignDetailed StepsDetailed Steps

COPYRIGHT DASSAULT SYSTEMES 2002 Version 5 Release 8March 2002EDU-CAT-E-MTD-FS-V5R8

Mold Tooling Design Detailed Steps

Table of ContentsMaster Exercise : The Phone Handset........................................................................................................3

Step (1): Creating a new Mold................................................................................................................. 3

Step (2): Editing the Mold Base................................................................................................................9

Step (3): Creating Components..............................................................................................................12

Step (4): Editing Components................................................................................................................25

Step (5): Creating Injection Features.....................................................................................................28

Step (Creating a Slider mechanism)......................................................................................................36

Step (Managing User Components).......................................................................................................54

COPYRIGHT DASSAULT SYSTEMES 2002 2


Master Exercise : The Phone HandsetStep (1): Creating a new MoldIn this step, you will: Access workbench Mold Tooling Design Create a new Product Insert existing Molded Part Select a Mold Base in a Catalog Position the Molded Part in the Mold Base

1. Enter workbench Mold Tooling Design to start a new Product :

2. Insert existing Molded Part :

a. Select new Product in the specification tree

b. Activate function Insert / Existing Component…

c. Select file \MasterExercise\Step1\MoldedPart.CATPart :



d. In Open Body PartingBody, show CoreSurface :

3. Select a Mold Base in a catalog :

a. Click icon Create a new mold :

b. Click Catalog icon in dialog box Create a new mold…

c. Double-click successively reference Dme, then N3050 in the Catalog browser dialog box (select reference N3050 without overhang, i.e. the first one displayed in the list) :



d. Click OK to validate : a graphic preview of the Mold Base is displayed and the dialog box Create a new mold…is updated with the list of plates and default dimensions corresponding to this reference :

e. Select in the dialog box the design table icon corresponding to Cavity plate, select reference whose height = 86mm, and click OK to validate



f. Proceed similarly to adjust also Core Plate height to 86 mm and Riser bar height to 106 mm :

g. Click OK to validate : you can see that sub-product Mold has been created in the specification tree. You can also notice that the Mold Base comes with many DME-predefined location points to help position other components : circle points for guiding or locating elements (Leader Pins, Sleeves, Bushings), cross points for fixing elements (Cap Screws), star points for specific components (Locating Ring).



4. Adjust the position of the Molded Part in the Mold Base, using the Manipulator :

a. Click icon Manipulation :

b. Click icon Top View :

c. Drag graphically the Molded Part along axis X to ensure that the Core Surface completely splits the Core Plate

d. Click icon Left View :

e. Proceed similarly to drag Molded Part along Z axis to position it in the overlapping area of the Core Plate and Cavity Plate :



f. Click OK in dialog box Manipulation Parameters to validate the positioning. The result should look as shown :



Step (2): Editing the Mold BaseIn this step, you will: Split the Core Plate Split the Cavity Plate

1. Open existing Mold Product \MasterExercise\Step2\Product1.CATProduct. You can notice that dedicated Mold icons are displayed in the specification tree. These icons are displayed only once the Mold Product has been saved, not during interactive creation.

2. Activate (MB3) the contextual menu of the Cavity Plate and select function Split component… :

3. The system offers CavitySurface (located in PartingBody of the Molded Part) as default value for the splitting surface : click OK in the Split dialog box to accept this default value :



4. Proceed similarly for the Core Plate, accepting default value CoreSurface

5. The result should look as shown. Hide the Molded Part, then alternatively hide InjectionSide and EjectionSide to check the results :



Step (3): Creating ComponentsIn this step, you will: Create Guiding components : Leader Pins and Bushings Create Locating components : Sleeves Create Ejection components : Ejector Pins Create Fixing components : Cap Screws

You will learn how to use predefined points to instantiate a component, or to position it on a face.

1. Open existing Mold Product \MasterExercise\Step3\Product1.CATProduct.

2. Create Leader Pins :

a. Click icon Add Leader Pin :

b. In dialog box Catalog Browser : Leader Pin, double-click reference Dme :



c. Now double-click reference LeaderPin_FSC :

d. You can see that the system has applied a predefined filter to display only the references of this type which are relevant. In this case, the filter applied (D=20mm) corresponds to the diameter recommended by the supplier.



e. Double-click reference FSC-20-36-146 :

f. Use predefined point located in the corner of the Clamping Plate to position the first instance of the Leader Pin :

g. You can notice that the system has automatically recognized all 4 predefined points intended for positioning the leader Pins. The current instance is highlighted in red, the others in green.

In dialog box LeaderPin definition, click button Reverse Direction to orient the Leader Pin downwards, then select graphically the Clamping Plate as plate Drill From, and the Cavity Plate as plate To :



h. Click OK in the dialog box to validate the creation. You can see that all four instances of the Leader Pin have been created, together with their associated holes in the impacted plates. They also have been created in the specification tree, in sub-assembly InjectionSide :

3. You can now proceed similarly to create Bushings fitting these Leader Pins, using the predefined points located in the Core Plate for this purpose. Select Dme reference Bushing_FBC . You can see that the system applies a predefined filter to display only the recommended references : select reference FBC-20-46. Drill from CorePlate to CavityPlate :



4. You can now proceed similarly to create the appropriate Sleeves for these Leader Pins. Select Dme type Sleeve_TD, reference TD-32-120. Note that the filter applied by the system takes into account the inner diameter of the Leader Pin and the height of the Risers. Drill from SettingPlate to CoreSupportPlate and adjust Z value to –160 mm (note that Z position is adjusted independently for each Sleeve instance).



5. Create Ejector Pins :

a. To make easier the visualization and the positioning of the Ejector Pin, hide InjectionSide, EjectorPlateB and SettingPlate



b. Go to Tools/Options/Mechanical design/Mold Tooling Design/Component and mske sure that option Several Instances per Reference is not active for the type of component Ejector Pin. This will ensure that a CATPart is created for each instance of the component, and therefore that each instance can further be handled individually if necessary.

c. Double-click part EjectorPlateA in the tree and make sure that workbench Wireframe and Surface Design or Generative Shape Design is active. Make sure that Open body.2 is the current active body.

d. Select the bottom face of EjectorPlateA and click ison Sketcher



e. Double-click icon Point, define several points to locate later Ejector Pins, then exit Sketcher.

f. Double-click top Product to go back to workbench Mold Tooling Design.

g. Click icon Add Ejector Pin and select in Hasco catalog reference EjectorPin_Z441. The system has applied as filter the distance between the bottom of EjectorPlateA and the top of the rough CorePlate (i.e. without taking account the split of this plate).



h. Double-click the proposed reference : Z441/2x250 and pick one of the points of the sketch previously created. You can see that the system has created and positioned an Ejector Pin on each of the points of the Sketch.

i. Define drill from EjectorPlateA to CorePlate.

j. You can see that a white dashed line in the preview materializes the height of the hole associated to each Ejector :



k. You can see that this hole is too high : the Ejector Pins would not be fitted closely to the Core Surface, and liquid plastic would leak into the interstice constituted by this hole in the Core surface. You have to interactively adjust this length via parameter Offset_Parting in tab Parameters of dialog box EjectorPin definition (for each EjectorPin, change value from 10mm to 30mm approximately, depending on its position). Validate the creation of the Ejector Pins.

l. You can see that the Ejector Pins have been created in sub-assembly EjectorSystem :



6. Insert Fixing Component : Cap Screw

a. First, show InjectionSide, EjectorPlateB and SettingPlate which had been put in NoShow

b. Click icon Add Cap Screw and double-click in Dme catalog type CapScrew_M, then reference M12*120. Select the predefined point materialized by a cross in the corner of the Setting Plate : it may be necessary to choose a reference a little bigger and longer, but you can perform this later (editing a component already created). Drill from SettingPlate to CoreSupportPlate. You can see that, as for Leader Pins, the system has automatically identified the other relevant points for placing screws and has created 3 other instances.

c. You can see that SettingPlate and Risers have been drilled with standard holes, while the last plate (CoreSupportPlate) has been bored with a threaded hole.



Step (4): Editing ComponentsIn this step, you will: Edit the definition of a component : Cap Screws Split a component : Ejector Pins

1. Open existing Product \MasterExercise\Step4\Product1.CATProduct :

2. Edit the definition of the Cap Screws : change the reference :

a. Select a CapScrew instance in the specification tree, activate its contextual menu and select function Edit CapScrew component :

b. Select tab Parameters in dialog box Edit CapScrew, activate design table icon corresponding to parameter L (length) and select reference M16*140



c. Validate the modification : you can see that all four instances of the Cap Screw have been updated simultaneously :

3. Put InjectionSide in Noshow

4. Split the Ejector Pins : multi-select the Ejector Pins in the specification tree and activate function Split Component in the contextual menu. Then validate the default value proposed by the system (CoreSurface) as splitting element and zoom onto Ejector Pin area to check the result.



Step (5): Creating Injection FeaturesIn this step, you will: Create a Gate Create a Runner Create a Coolant Channel

The final result is available as \MasterExercise\Step5\End\Product1.CATProduct.

1. Open existing Product \MasterExercise\Step5\Product1.CATProduct and show only PartingLine in MoldedPart.

2. Create a Gate :

a. Click icon Add Gate

b. Create the location point of the Gate : Click icon Point, and define the point as a Point On Curve, select PartingLine as support curve and enter Ratio of Curve length = 0.7. Click Apply in dialog box Point Definition to check the position. Validate the creation.

You can see that the point has been created in the Molded Part in an Open Body named GateBody, and that it is graphically materialized by a yellow square.



c. Define Gate parameters : in dialog box Gate definition, click catalog icon and double-click type SideGate, then SideRound, then Round, and set value Radius = 1 mm. You can see that a preview of the Gate is displayed. Validate the creation.



3. Create a Runner :

a. Double-click in the specification tree Part MoldedPart and enter workbench Part Design, or Generative Shape design, or Wireframe and Surface Design

b. Select plane XY and enter the sketcher. Make sure grid option icon Snap to Point is deactivated.



c. Click icon Profile, and draw a profile approximately as shown, ensuring tangency continuity all along (use for example dialog box Constraint Definition for this purpose). This is mandatory to ensure a correct projection of the sketch onto PartingSurface, when creating the Runner in the next step.

d. Now ensure coincidence between the Gate point (yellow square) and the extremity of the Runner : multi-select them, activate dialog box Constraint Definition and activate Coincidence.

e. Now exit Sketcher, and double-click top Product in the Specification tree to come back to workbench Mold Tooling Design.



f. Click icon Add Runner, switch section type to Oval, set Radius value = 2.5 mm and select the new sketch as Layout. Validate the creation. Hide the Gate point to check the result more clearly.

4. Create a Coolant Channel in the Cavity Plate :

a. In sub-assembly EjectionSide, double-click CoreCooling and make sure that workbench Generative Shape Design or Wireframe and Surface Design is active. Make sure Open_body.1 is the current active open body or create a new open body.

b. Click icon Plane, select type Offset from plane and select plane XY as reference plane. Adjust the position by dragging the green arrow. Validate creation.



c. Select the new plane, click icon Sketcher, create successively two lines as shown :

d. Exit Sketcher and switch back to workbench MoldTooling Design.

e. Select the new sketch in the tree, then click icon Add Coolant Channel. The system offers a direction for one of the cooling pipes and a small dialog box is displayed to reverse the proposed direction if wanted.



f. Click OK several times to validate the choices proposed, then adjust if desired the definition of the dimensions in dialog box Coolant Channel definition.

g. To edit the definition of the Coolant Channels, put Core Cooling/Open_body.1 in Show and double-click the Sketch to modify it as desired. For example, drag the extremity of one line to go through the opposite extremity of the CorePlate.



Step (Creating a Slider mechanism)In this step, you will: Create a Slider component Create the corresponding Retainers Create the corresponding Angle Pin Create the fixing screws and perform the relevant drillings

1. Open existing Product \MasterExercise\SliderMechanism\Start\PreparedProduct.CATProduct and put InjectionSide in NoShow.

2. Create a Slider :

a. Click icon Add Slider, then double-click the Slider listed in the catalog window.



b. Click the top face of the Core Plate located in front of the rectangular hole in the part where the Slider mechanism is required.

c. the system switches to the sketcher-like view for positioning the component. Pick a point on the previous face : a preview of the Slider is displayed.



d. Adjust Slider position by rotating it using the green half-circle.

e. Switch to Left View and display tab Parameters in dialog box Define slider.



f. Adjust the value of the following parameters : W=30mm, WT=7mm, HT=10mm. Adjust the position to X=-140mm, Y=0mm, Z=10mm.

Then adjust Retraction=5mm and note the update of the angle for the Angle Pin hole.



g. Define the plates to be drilled : From CorePlate To CavityPlate in tab Positioning.

h. Validate the creation of the Slider.

2. Split the form part of the Slider :

a. In PreparedMoldedPart, show surface SliderSurface located in open body PreparedSurfaces.



b. Activate function Split Component… in the contextual menu of the Slider

c. Select surface SliderSurface and activate the display of the Split direction in dialog box Split definition.



d. Click one of the displayed direction arrows in order to invert the sense of the Split and ensure that the right side of the form part is split.

3. Create the Retainers :

a. Click icon Add Retainers, then double-click the Retainers listed in dialog box Define Retainers.



b. Pick the face on the Core Plate where the Slider will move

c. Pick a point on this face to position the Retainers. A preview of the component is displayed. Adjust its position (rotation) by using the green half-circle.



.

d. Switch to Back View. Then click the Slider in the 3D viewer : some of the dimensions of the Retainers are automatically adjusted to fit the Slider.

Note : Make sure that there is no selection of another object than the Slider itself, otherwise the system will consider that another instance of the Retainers has to be created at the location of the pick.



e. Switch to Top View. Define plates drill from CorePlate to CavityPlate. Adjust the position and the length of the Retainers to ensure adequate contact length between the Slider and the Retainers. Define for example : L=100mm, X=-190mm, Y=0mm, Z=10mm. Validate creation.



4. Create the Angle Pin :

a. Click icon Add Angle Pin. Select in catalog DME type AnglePin_APD, then double-click variant APD-10-110



b. To position the AnglePin, select the line, then the point previously created with the Slider for this purpose.



c. Drill From CavityPlate To CorePlate. The Z position will be adjusted later via Edition capability. Validate creation.

d. Show complete InjectionSide, switch to Left View. Activate function Edit AnglePin Component in the contextual menu of the AnglePin.



e. Adjust the Z position of the Angle Pin. Set e.g. Z=110mm. Validate.

5. Create the Screws to fix the Retainers :

a. Put InjectionSide in NoShow.

b. Double-click sub-assembly EjectionSide : standard drilling mechanism (Drill From… To) operate sonly on plates, not on components, like the Retainers. Therefore, making InjectionSide the current component will ensure that the Screws are located there.



c. Click icon Add CapScrew. Select in catalog Rabourdin type CapSCrew_527, then double-click variant 527-3x30.

d. Pick the top face of the Retainers. Pick four points to create four instances of the CapSCrew. Click button Reverse Direction in dialog box Define CapScrew to ensure proper orientation. Sink the screws inside the Retainers. Validate creation.



6. Create the drillings for the Screws :

a. Activate function Tools/Drill Component…

b. Successively drill the Retainers with the DrillHole of each CapScrew.



c. Similarly, drill the CorePlate with the TapHole of each CapScrew.



Step (Managing User Components)In this step, you will: Create a User Catalog with your own type of Sliders Link your catalog to the master User Component catalog

1. Enter workbench Catalog Editor

2. Activate function Definition… in the contextual menu of the default chapter Chapter.1

3. Rename the Chapter with the name you wish, e.g. MySliders



4. Click icon Add family and name it for example SliderDPA. Validate creation.

5. Double-click in the tree family SliderDPA. Click icon Add Component.

6. Give a name to the component (e.g. SliderDPA-1). Click button Select document in dialog box Description definition. Select file SliderDPA-1.CATPart in folder \MasterExercise\userComponents.. Validate creation.



7. Select component SliderDPA-1. Click icon Add Keyword. Create a Keyword of type String, name it for example ModelType, and give it the default value ModelSimple. Validate creation.



8. Add another component, referencing file SliderDPA-2.CATPart.

9. Save your catalog, e.g. under name MyOwnCatalog, in any folder you wish.



10. Open master catalog of user components (make sure first it is not Readonly).

\intel_a\startup\componets\MoldCatalog\UserComponent.catalog.

11. Click Window/Tile Horizontally.



12. Make sure that window UserComponent.catalog is active. Click icon Add link to other catalog. Select chapter MySliders in window MyOwnCatalog.catalog : the chapter has been added into the master User Component catalog.

13. Select Keyword Supplier for the new chapter. Activate function Definition… in the contextual menu. Select tab Keyword values. Define a value for keyword Supplier, e.g. InternalDesignSliders. Validate.



14. Save file UserCompnent.catalog. It is now ready for use.


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