Mold Design & Manufacturing Process(Catia)

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IBM PLM / IBM Business Partners / Dassault Systemes Internal Use Only

V5R13 Generative Mold - Design & Manufacturing

Mold Design & Manufacturing Process

CATIA Demonstration Script

Version 5 Release 13February 2004C513_demMold_Script_DesignManufacturing

The demonstration Image Medium size 400X300

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V5R13 Generative Mold - Design & Manufacturing Setting up CATIA Environment

Setting up CATIA Environment Erase previous Settings

If your CATSettings folder has not been created in V5R13, you must first physically delete it and restart CATIA.

The file is located in folder C:\Documents and Settings\user_name\Application Data\DassaultSystemes

Tool/Options Click button “Resets parameters’

values to default ones” and select option “for all the tabpages”

This is necessary only if the previous erase has not been done

Tools/Options/General : General : set “Data Save : No

automatic backup” Display/Performances : set “3D

Accuracy : Fixed = 0.01”

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Setting up CATIA Environment

Tools/Options/General : Parameters and

Measures/Knowledge : activate “Parameter Tree View : With value & With formula”

Tools/Options/Infrastructure : Product Structure/Tree Customization

: activate Specification Tree Order : Parameters, Relations, Constraints

Part Infrastructure/Display : activate “Display In Specification Tree : Constraints, Parameters, Relations”

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Setting up CATIA Environment

Tools/Options/Mechanical Design : Assembly Design/General : set

“Update : Automatic” Sketcher : deactivate “Grid : Snap to

point” Tools/Options/NC Manufacturing :

Photo/Video : set “Simulation at : Part operation level”

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V5R13 Generative Mold - Design & Manufacturing Demo Steps

Step 1 Data Check and Repair

Step 2 Applying local Deformation

Step 3 Core & Cavity Separation

Step 4 Parting Surface Definition

Step 5 Mold Tool Design

Step 6 Mold Tool Drawings

Step 7 2.5- and 3-Axis Manufacturing

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V5R13 Generative Mold - Design & Manufacturing Step 1 : Data Check and Repair

Check Input data : Face Validity Enter workbench Healing Assistant Open Design Part

Open file \Step1-InputDataCheck&Repair\Begin\ CarHandle.CATPart

Part has previously been read from IGES file

It is made up of about 210 independent surfaces

Check intrinsic validity of all surfaces Multi-select all surfaces Click icon Face Checker Keep Self-Intersection default value :

0.001 mm Click button Apply

One Face is diagnosed with Self-Intersection

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Repair Input data : Face Validity Separate invalid surfaces :

Click button Transfer In dialog box Transfer, activate

Reframe On in contextual menu of the line Site.1

Corresponding face is highlighted in the 3D viewer

Click Move button to move Site.1 from list Anomalies Detected to list Anomalies Selected

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Repair Input data : Face Validity Repair invalid surfaces :

Activate option Automatic Repair Click button Close

Surface.92 has been identified as invalid and a new repaired Surface has automatically been created and put in a dedicated separate Geometrical Set

The initial invalid surface is automatically put in NoShow in a dedicated separate Geometrical Set

In dialog box Face Checker, click OK to validate the operation

Hide all elements except the faulty surface and zoom :

The extremities are very sharp : the boundary of the face is probably not clean enough and some of its edges are crisscrossing.

Delete Geometrical Set containing original invalid surface Surface.92

Put back the remaining elements in Show

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Check Input Data : Face Connections Analyze quality of connection between

all surfaces : Multi-select all visible surfaces Click icon Surface Connection Checker :

Default value for Connection distance = 0.001 mm

Default value for Search distance = Regular = 0.1 mm

These values give the range (min/max) of analysis

Below the min value, two edges are considered as identical. It corresponds to the target value of the Join to be performed later to concatenate these independent surfaces.

Between min and max values, two edges are candidates for merging via Local Join or Local Healing operations

Beyond the max value, elements correspond to functional holes and should not be Joined or are defect faces that should undergo repair before being Joined.

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Check Input Data : Face Connections Change value of Connection distance to

0.01 mm : this is a realistic target value for the future Join of all Surfaces

Click Apply The dialog box displays analysis results for

all criteria : Duplicate, Embedded, Multiple Connection,…

All results are computed simultaneously : by selecting one criterion in the list, you switch the graphical highlight in the 3D viewer to the current active criterion (e.g. Duplicate displayed in purple, Multiple Connection in dark blue, etc.

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Check Input Data: Duplicate Faces Focus first on duplicate surfaces :

Make sure that the current selected option in the dialog box is Duplicate : 1 duplicate face has been detected

Separate duplicate surfaces : Click button Transfer In dialog box Transfer, click Move

button to move Site.1 from list Anomalies Detected to list Anomalies Selected

Click button Close A new Geometrical Set has

automatically been created to group together the two surfaces detected as identical

In dialog box Surface Connection Checker, click button OK to validate the operation

Delete redundant surfaces : Delete Geometrical Set called Surplus

to eliminate one of the identical surfaces

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Check Input Data : Embedded Faces Focus now on embedded surfaces :

Multi-select all visible surfaces Click icon Surface Connection Checker Keep values : Search distance = Regular

= 0.1 mm and Connection distance = 0.01 mm

Click Apply to perform analysis for all criteria

Select criterion Embedded One location has been detected

Separate embedded surfaces : Click button Transfer In dialog box Transfer, click Move button

to move Site.1 from list Anomalies Detected to list Anomalies Selected

Click button Close A new Geometrical Set has been created

In dialog box Surface Connection Checker, click button OK to validate the operation

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Repair Input Data : Embedded Faces Delete unnecessary surfaces :

Put the new Geometrical Set in Show mode

Hide Surface.130 : you can see that Surface.129 is embedded in Surface.130

Delete Surface.129

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Check Input Data : Overlaps Focus now on overlapping surfaces :

Multi-select all visible surfaces Click icon Surface Connection

Checker Keep previous values : Search

distance = Regular = 0.1 mm and Connection distance = 0.01 mm

Click Apply to perform the analysis for all criteria

Select criterion Overlap 4 locations have been detected Note that solving the duplicate and

embedded cases first has helped reduce the number of overlaps, which was equal to 6 after the first Surface Connection Checker analysis.

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Repair Input Data : Overlaps Separate overlapping surfaces :

Click button Transfer In dialog box Transfer, click Move All


Click button Close A new Geometrical Set has automatically

been created to group together the surfaces causing the problem

Click button Transfer

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Repair Input Data : Overlaps In dialog box Transfer, click Move All


Click button Close A new Geometrical Set has automatically

been created to group together the surfaces causing the problem

Prepare rework of the surfaces : Show the newly created Geometrical Set Change the colour of its surfaces (e.g.

light blue) to recognize them more easily

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Repair Input Data : Overlaps First rework action : delete

unnecessary surface : Delete Surface.147 which is

superimposed on Surface.257 Second rework action : replace

surface causing overlap : Focus on connection between

Surface.78 and Surface.84 Zoom in to check the overlap visually Delete Surface.84 Create a new Geometrical Set and make

it current

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Repair Input Data : Overlaps Click icon Create datum Click icon Fill Select the edges of the neighbour

surfaces to create a new Surface as shown Click OK to validate creation

A warning message informs you that there is a 0.01 mm gap between the element

No further action is required now : this gap will be handled later via the Merging distance of the Join operation

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Repair Input Data : Overlaps Third rework action : trim extremity of

surface causing overlap : Focus on connection between

Surface.78 and Surface.62 Zoom in to check the overlap visually

You can see that the sharp extremity of Surface.78 is deeply overlapping with Surface.62

There are no neighbour edges which can be reused directly to replace this sharp Surface by a new one, so we are going to trim its extremity

Click icon Create datum Click icon Boundary and select

Surface.78 Click OK to validate creation of boundary

Curve Hide Geometrical Set.1 for better

visualization

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Repair Input Data : Overlaps Click icon Create datum Click icon Projection Select Projected = boundary Curve Select Support = Surface.62 Click OK to validate operation Hide original boundary Curve Click icon Create datum Click icon Line and select User type =

Point-Point Pick successively the two vertices of

the projection Curve Select Support = Surface.62 Click OK to validate creation Click icon Create datum Click icon Projection Select Projected = line Curve Select Support = Surface.78 Click OK to validate operation

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Repair Input Data : Overlaps Click icon Create datum Click icon Split Select Element to cut = Surface.78 Select Cutting element = projected

Curve Make sure the appropriate side of

Surface.78 is pre-visualized Click OK to validate operation Delete the wireframe construction

elements previously created Delete Surface.78

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Repair Input Data Create Join with all Surfaces

Show Geometrical Set.1 Create a new Geometric Set Multi-select all visible surfaces Click icon Join Deselect option Check Connexity Set merging distance = 0.01 mm Click OK to validate

Compute remaining free edges Select Join Click icon Boundary Click OK Click No in dialog box Multi-result

management in order to keep all sub-elements

The Boundary is created

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Repair Input Data Repair remaining free edges with

Local Join+Healing Select new Boundary Click icon Local Join

Default option is Join You can see that the system has

computed the minimum Merging Distance for the join : 0.05 mm

Set Join Merging Distance = 0.05 mm

Select option Automatic Join/Heal Click Apply

There are no visible free edges (green display)

Click OK to validate

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Repair Input Data Check Join closure

Select Local Join Click icon Boundary

A message informs that the Join is closed

Click Cancel to cancel Boundary creation

Close without Save

End of Step 1. Result data is : \Step1-InputDataCheck&Repair\End\

CarHandle.CATPart

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V5R13 Generative Mold - Design & Manufacturing Step 2 : Applying local Deformation

Local Part Deformation Dedicated analysis or previous

experience show that the inner hole is subject to deformation when hot plastic injection is done.

To offset this effect, the opposite deformation can be applied to the original shape to ensure that the final result is really a round hole.

This deformation will be applied thanks to function Shape Morphing (workbench Generative Shape Optimizer is necessary).

Applying the deformation will be applied in a quick and convenient way thanks to Powercopy capability.

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Applying local Deformation Open the Design Part :

Open file \Step2-LocalDeformation\Begin\CarHandle.CATPart

Make sure that Generative Shape Design is the current active workbench

Select PowerCopy of Part Deformation Template

Click Insert / Instantiate From Document…

Select file \Step2-LocalDeformation\Begin\PowerCopyLocalDeformation.CATPart

Dialog box Insert Object is displayed The Design Part is going to be modified to

change the shape of the inner hole from round to ellipsoidal in order to compensate for the deformation during the injection operation.

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Applying local Deformation Select the Part to be deformed

Pick the Local Join feature This corresponds to expected

PowerCopy input named PartSkin

Select the original round hole curve Pick prepared red curve called

OriginalCurve-Circle This corresponds to expected

PowerCopy input named InitialCurve

Select the target ellipse curve Pick prepared green curve called

TargetCurve-Ellipse This corresponds to expected

PowerCopy input named DeformedCurve

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Applying local Deformation Define two fixed curves to control the

deformation of the Part Pick the edge at the extremity of the Part

as shown This corresponds to expected PowerCopy

input named FixedCurve-1 Pick the edge on the upper side of the

Part as shown This corresponds to expected PowerCopy

input named FixedCurve-2 Define a limit curve to control the

propagation of the deformation Pick the edge as shown

This corresponds to expected PowerCopy input named CurveForNormalPlane

This edge will be used by the PowerCopy to compute a normal plane through it. The intersection of this plane and the Part will be the limit curve to propagate the deformation

Make sure the green arrow is oriented as shown in order to define the correct orientation for propagating the deformation.

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Applying local Deformation Pick the vertex as shown

This corresponds to expected PowerCopy input named PointForNormalPlane

This point will be used by the PowerCopy to compute the normal plane, then the limit curve mentioned before.

Create the deformation Click button Preview to check the

computed result Click OK to validate the creation of

the Shape Morphing feature Hide Local Join to better visualize

the final result Close without Save

End of Step 2. Result data is : \Step2-LocalDeformation\End\

CarHandle.CATPart

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V5R13 Generative Mold - Design & Manufacturing Step 3 : Core & Cavity Separation

Create Molded Part Import Part to mold

Create new empty Product and make it active (highlighted in orange)

Enter workbench Core & Cavity Design Click icon Import model Select Reference = \Step3-

CoreCavitySeparation\Begin\CarHandle.CATPart

Select Body = DeformationElements Surface Shape Morphing.1 is automatically

selected Select Axis System = Local axis system Select shrinkage : Scaling Ratio = 1.01 Click OK to validate Reframe on the Part

A solid element (ClosedSurface) has been created and the corresponding scaling value has automatically been applied

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Define Main Pulling Direction Define Mold areas

Click icon Define pulling direction Drag and drop compass origin (red

square point) onto the bottom of the inner hole of the part

Click anywhere on the part A coloured display shows the mold areas

of the part : Core in Red, Cavity in Green, Other (to be reworked) in blue, and No Draft (vertical faces, according to value of Draft angle) in pink

Click button Reverse if necessary This is to ensure that Z+ axis of the

pulling direction is oriented towards the outer side of the Part and that Core side (red) corresponds to the inner side of the Part

Activate option Locked This will prevent any erroneous

displacement during further operations

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Define Main Pulling Direction Refine mold areas : Facets to ignore

Zoom in onto one of the blue faces located among the Core side

Select option Visualization = Facet display to check the defects

You can see that these faces are not quite moldable because of insufficient quality of design.

However, the defects are not too big, so we will reassign these faces to Core side.

A similar analysis could be done for other blue faces

Select option Visualization = Face display

Activate option Facets to ignore Keep default maximum ratio value (15 %) You can see that many blue faces have

been automatically transferred to Core side or Cavity side

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Define Main Pulling Direction Refine mold areas : Explode mode

Activate option Visualization = Explode Set the translation value to 50mm

Core side (red faces) and Cavity side (green faces) are moved apart accordingly, thus enabling to see more clearly which remaining blue faces could be redistributed to Core or Cavity areas.

Refine mold areas : Local Transfer to Core

Activate option Local Transfer Keep default destination = Core Select propagation type = No

propagation Click the two blue faces as shown

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Define Main Pulling Direction Refine mold areas : Local Transfer

to Cavity Select default destination = Cavity Keep propagation type = No

propagation Click the blue faces as shown Click OK to validate the creation of the

Mold areas. Further rework has still to be done Four Geometrical Sets have

automatically been created : Core, Cavity, Other, NoDraft

An Axis System has automatically been created (Main Pulling Direction.1)

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Define Slider area Define Slider area

Click icon Defines slider lifter direction Drag and drop the compass onto the

inner face of the undercut area Note that the corresponding face has

switched from pink to yellow, which is the typical colour of a Slider/lifter area

Activate option Locked Activate option Local Transfer Keep default destination = Slider/Lifter Select propagation type = Point

continuity Pick successively pink, blue, green and

red faces of the undercut area Click OK to validate

A new Geometrical Set has automatically been created : Slider/Lifter.1

An Axis System has automatically been created (Main Pulling Direction.1)

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Refine Mold areas : Reflect Line Compute Reflect Line

Create a new Geometrical Set Zoom onto the remaining blue area :

this region of the Part has to be reworked because the Reflect Line corresponding to the Main Pulling Direction is crossing it.

Hide Mold areas Other, Core, Cavity Show Part Body

The Reflect Line will be computed on the corresponding region of thePart itself. It is not computed on the Mold area, since this Mold area will then be split by the Reflect line (it would cause a logical loop).

Click icon Reflect Line Select Support = Scaling.1 Select Direction : Z axis of Main

Pulling Direction Select Angle = 90 deg Click OK to validate

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Refine Mold areas : Reflect Line Restrict Reflect Line

Click Yes in dialog box Multi-Result Management

The Reflect Line is made up of several discontinuous pieces : we will keep only the relevant piece

Pick one face or edge near the desired piece of the Reflect Line


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Refine Mold areas : Split by Reflect Line

Split Mold area Other Hide Part Body Show Mold areas Other, Core, Cavity Click icon Split mold area Select propagation type = Point

continuity Pick one blue face Select Cutting Element : Near.1 Keep default destination = Core Click Apply Click button Switch Destination if

necessary to ensure the appropriate side of the Split goes to the Core area


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Refine Mold areas : Transfer Faces Transfer remaining blue faces to

Cavity area Click icon Transfer an element Select Propagation type = Point

continuity Select Destination = Cavity Pick one blue face Click OK to validate

Final check Click icon Explode View Set Explode Value = 50 mm Click Cancel to close Exploded View

Close without Save End of Step 3. Result data is : \Step3-CoreCavitySeparation\End\

Product1.CATProduct

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V5R13 Generative Mold - Design & Manufacturing Step 4 : Parting Surface Creation

Define External Parting Surface Open Molded Part

Open file \Step4-PartingSurfaceCreation\Begin\MoldedPart.CATPart

Enter workbench Core & Cavity Design

Aggregate Mold areas Click icon Aggregate Mold Area Select Geometrical Set Core Activate option Create a join datum Validate

Core side is now a single connex surface without free edges

Repeat previous operations on Cavity side.

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Define External Parting Surface Start creating Parting Surface

elements Click icon Parting surface Deactivate option Join Parting Surface

Start with Cavity side Pick the Cavity area as Reference

Support Create first Extrude

Successively pick the two vertices as shown

The piece of boundary between the two vertices is highlighted in green

Pick the line of the prepared sketch as shown

An Extrude surface is created The sketch is located in the plane

orthogonal to the Main Pulling Direction

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Define External Parting Surface Create second Extrude



An Extrude surface is created

Create third Extrude Successively pick the two vertices

as shown Pick the line of the prepared sketch

as shown An Extrude surface is created

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Define External Parting Surface Create fourth Extrude


Pick the side of the prepared sketch as shown


orthogonal to the Slider Pulling Direction

Create first Loft Click icon Multi-section Surface in

the dialog box Successively pick the two vertices

as shown Successively pick the two sections

as shown (reverse orientation of first section with red arrow)

A Multi-section surface is created

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Define External Parting Surface Create second Loft


Successively pick the two sections as shown (reverse orientation of first section with red arrow)

A Multi-section surface is created This Surface will be reworked later

to add tangency constraint in order to get a smoother shape

Continue with Core side In the dialog box, click icon Extrude In the dialog box, select field

Reference In the 3D viewer, pick the Core area

as Reference Support

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Define External Parting Surface Create Extrude


The piece of boundary between the two vertices is highlighted in green



orthogonal to the Main Pulling Direction

Validate creation of all surfaces Click OK in dialog box Parting

Surface Creation You can see that the corresponding

surfaces have been created as Extrude and Multi-sections Surface features

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Define External Parting Surface Rework a previous surface to add

tangency Double-click the Multi-section surface

as shown In the dialog box, select line of

Section no.1 In the 3D viewer, pick the neighbour

Extrude Surface as shown Tangency constraint is added

Click OK to validate the modification

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Define External Parting Surface Create last surfaces : Sweep

Click icon Sweep Select as Profile the edge of the

Extrude as shown Select as Guide Curve the edge of

the Extrude as shown Click OK to validate Create another Sweep surface as

shown The definition of the outer Parting

Surface is now complete

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Define Splitting Surfaces Start defining splitting surfaces

Create a new Geometrical Set and call it SplittingSurfaces

Fill functional Hole Click icon Fill Select the edges of the inner hole Click OK to validate

Join external Parting Surface elements common to Cavity side and Core side

Click icon Join Multi-select adequate surfaces created

previously (in light blue on the picture) Set Merging distance = 0.01 mm Click OK to validate

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Define Splitting Surfaces Create complete splitting surface for

Cavity Side Click icon Join Multi-select adequate surfaces : Cavity

area, Fill surface, previous Join, specific Extrude (in dark blue on the picture)

Set Merging distance = 0.01 mm Click OK to validate Rename new Join as CavitySurface Change its colour to dark green

Create complete splitting surface for Core Side

Proceed similarly to create a Join for the Core side

Specific Extrude is in light pink on the picture

Rename new Join as CoreSurface Change its colour to dark pink

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Define Splitting Surfaces Create complete splitting surface

for the Slider Click icon Join Multi-select adequate surfaces :

Slider area, specific Extrudes (in dark blue and light pink on the picture)

Set Merging distance = 0.01 mm Click OK to validate Rename new Join as SliderSurface Change its colour to bright yellow

Close without Save

End of Step 4. Result data is : \Step4-PartingSurfaceCreation\End\ MoldedPart.CATPart

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V5R13 Generative Mold - Design & Manufacturing Step 5 : Mold Tool Design

Reuse existing User Mold Base Template

Enter workbench Assembly Design Create a new empty Product

Select the Mold Base Template Click icon Catalog Browser In the dialog box, click icon Browse

another catalog In dialog box File selection, double-

click \Step5-MoldToolDesign\Begin\UserMoldBases.catalog

There are two categories of templates in the catalog

Double-click item named Type-TwoPrints

Double-click item named SmallSize

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Create the Mold Base Double-click item named

TwoPrintsWithInserts Dialog box Insert Object is displayed,

showing the Product Template Click OK in dialog box Insert Object

A message informs you that the documents of the Template have been instantiated : the Mold Base Product, but also the prepared associated Drawing

Click OK to acknowledge the message Click Close in dialog box Catalog

Borowser The Mold Base Product is created Note that it already includes various

components : Leader Pins, Bushings, etc.

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Close the Drawing Select Drawing document in the list of

open documents Do not update it and save it with a

meaningful name in a folder of your choice.

We will focus on the drawing in a next step

A message informs you that the corresponding Product is modified but not saved.

Click Yes in message dialog box. Another message lists the details of

unsaved Product and Parts files. Click Yes in message dialog box.

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Insert Molded Part in Mold Assembly

Enter workbench Mold Tooling Design

Insert Molded Part in the Mold Base Select top Product

It is now highlighted in orange Select Insert / Existing Component Select file \Step5-MoldToolDesign\

Begin\MoldedPart.CATPart Click OK to validate

The Molded Part is now inserted in the Assembly, but its position has to be adjusted

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Insert Molded Part in Mold Assembly Adjust the position of the Molded Part

Hide Injection Side Click icon Snap First, select Axis System.3 (pale blue) in

the Molded Part Then select Axis System.2 (dotted line

yellow) in the Core Plate The Molded Part is now correctly

positioned on the first Insert instance of Core side

Adjust the size of both Inserts Activate icon Top View Select in the tree the first Insert instance In contextual menu, activate Insert

object / Edit Insert Component Select tab Parameters Set Insert width W = 140 mm Click OK to validate update of both

inserts

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Split the two Inserts Split the Insert instances

Double-click Part Insert_1_1.1 in the specification tree to make it active

Make sure the active workbench is now Part Design

Click icon Split In the Molded Part, select published

surface named CoreSurface Check the preview to ensure the kept

side is the one as shown Click OK in dialog box Split Definition Hide component Molded Part

You can see that both Insert instances have been simultaneously split

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Change Insert orientation Rotate second insert

Double-click top Product Make sure the active workbench is

now Mold Tooling Design Select in the tree the second Insert

instance In contextual menu, activate Insert

object / Edit Insert Component Select the rotation spinner (green half-

circle) In contextual menu, activate Edit angle Set Angle = 180 deg Click OK to validate in dialog box Edit

Insert The second Insert is now positioned

head-to-tail with the first one to allow for easier positioning of the Injection Gates and Runners

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Create Ejectors Define Ejectors’ locations

Double-click any of the pink sketch points

The Sketcher is now active Zoom in onto one of the inserts Drag and drop the existing two points

to relocate them approximately as shown Zoom in onto the second insert to

check that the two other points of the sketch have automatically been adjusted

This is because these points have been created symmetrical to the first ones

Click icon Exit workbench Double-click top Product in the tree to

switch back to workbench Mold Tooling Design

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Create Ejectors Select and position the Ejectors

Click icon Add Ejector Click the Open file icon Select file \Step5-MoldToolDesign\

Begin\Hasco\Ejector_Z41_1.CATPart This standard Hasco Ejector has

been customized to include a user-defined Knowledgeware Rule which will be described later

Pick any of the four pink sketch points

A preview of four instances of the Ejector is displayed

Click button Reverse Direction to define upward orientation

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Create Ejectors Define Ejector drillings

In dialog box Define Ejector, check that field Drill From has automatically been set to EjectorPlateB (this is the plate containing the sketch)

Select field To in order to make it current

In the 3D viewer, pick the Insert Field To is automatically updated

Click button Between From and To In the 3D viewer, pick successively

CoreSupportPlate and CorePlate In dialog box Define All

Components to Cross, click OK to validate the list

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Create Ejectors Define Ejector dimensions

In dialog box Define Ejector, select tab Parameters

Pick any of the two Design Table icons

In the Design Table dialog box, change the current configuration (D = 1mm, L = 200mm) to D = 1.5mm, L = 200mm

Click OK to validate this selection Note that the fitting length of the

Ejector is set to 10 mm (parameter Offset_Parting shown in the panel)

In dialog box Define Ejector, click OK to validate the creation of the four Ejectors

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Create Ejectors Split Ejectors

In the specification tree, multi-select the two Ejectors located in the first Insert

Activate in contextual menu : Selected objects / Split component…

Dialog box Split Definition is displayed

CoreSurface is automatically displayed as default choice for splitting

Click OK to validate Split operation Zoom in onto the two Ejectors to

see the result

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Create Ejectors Measure fitting length

Zoom in onto the Ejector located on the thickest side of the Insert

Click icon Measure Between Select the top edge of the split

Ejector Select the bottom edge of its fitting

tip (use arrow to select through the material)

This is the edge resulting from the Remove of DrillHole in the Insert

You can see that the fitting length = 10 mm, i.e. the value defined in Ejector’s parameter Offset_Parting

Click Cancel

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Create Ejectors Show Knowledgeware Rule to

adjust the fitting length In the specification tree, unfold node

Relations of the Ejector Part Highlight Knowledgeware Rule named

FittingLengthComputation Double-click it once to activate

workbench Knowledge Advisor Double-click it again to open the Rule

Editor dialog box and display the content of the Rule

This Rule enables to adjust the fitting length of the ejector to value Offset_Parting whatever the location of the Ejector

Click OK to close the Rule Editor dialog box

Double-click the top Product in the tree to switch back to workbench Mold Tooling Design

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Create Ejectors Change Ejector location

Select again the same Ejector in the tree

In contextual menu, activate Ejector object / Edit component

Click icon Top View Use the green arrow spinners to

drag the Ejector to the bottom of the pocket as shown

Click OK to validate the new location

Click icon Measure Between Select the top and bottom edges as

done previously You can see that the clearance hole

of the Ejector has been adjusted to keep the fitting tip length at 10 mm

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Create Slider Mechanism Prepare Slider positioning

Show Component Molded Part Hide Geometrical Set PartingBody

Green positioning point predefined in MoldedPart is now visible

Create dedicated sub-structure in the Mold Assembly

In the tree, double-click Product Mold to make it active

Select Insert / New Component Select Properties in the contextual

menu of the new component Set Part Number = MovingElements Click OK to validate In the tree, double-click the new

Component to make it active It is now highlighted in blue

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Create Slider Mechanism Select Slider Assembly

Click icon Add User Component Click the Open file icon Select file \Step5-MoldToolDesign\

Begin\SliderAssembly\DressedSlider.CATProduct

Define Slider position Pick green positioning point

predefined in MoldedPart A preview of the Slider Assembly is

displayed Use the green arc spinner to define

a 90-deg rotation The Slider assembly preview should

now look as shown

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Create Slider Mechanism Define Slider position

Click icon Top View Set position U = -5 mm Click Tab key to refresh the preview

Define the drillings Select field To Pick CorePlate in the 3D viewer

The CorePlate will be drilled by the DrillHolde of elements Slider, Retainers, AnglePin

The CorePlate will be drilled by the TapHole of elements CapScrews

Create Slider Assembly Click OK to validate creation

Check the drillings Hide component MovingElements to

show the drillings in the Core Plate Show again MovingElements

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Create Slider Mechanism Split Form part of the Slider

Zoom in onto the form part of the Slider

Select Component Slider in the Slider assembly user component

In contextual menu, activate Slider object / Split component…

Show Geometrical Set named PartingBody in the MoldedPart

In the tree, select surface named SliderSurface

Click button Display direction to check it as shown on the picture

Click OK to validate Split operation

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Create Slider Mechanism Final check

Hide PartingBody The form part of the Slider now fits

the undercut area Close without Save

End of Step 5. Result data is : \Step5-MoldToolDesign\End\

Product1.CATProduct

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V5R13 Generative Mold - Design & Manufacturing Step 6 : Mold Tool Drawings

Start from Drawing Template Open Tool Product

Open file \Step6-MoldToolDrawings\Begin\CarHandle-TwoInserts.CATProduct

Close dialog box with warning message

Open corresponding Drawing Open file \Step6-MoldToolDrawings\

Begin\TwoPrintsWithInserts.CATDrawing The template is made up of 3 views :

Front View of complete Mold from top, Section View of complete Mold – lengthwise, Section View of complete Mold – widthwise.

The predefined title block template will have to be updated (names, etc.)

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Create the Bill of Material Automatic numbering of the Parts

Select the Product in the list of open documents

Switch to workbench Assembly Design

In the specification tree, double-click Product Mold

It is now highlighted in orange Click icon Generate Numbering Keep default values (Mode =

Integer) Click OK to validate numbering

operation Create the Bill of Material

Select Analyze / Bill Of Material

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Create the Bill of Material Customize the Bill of Material

Click button Define formats In section Properties for the Bill of

Material, click button Hide all properties In section Properties for the

Recapitulation, transfer successively properties Nomenclature, Material and Number by using button Show properties

Click OK in dialog box Define formats

Click OK in dialog box Bill of Material

Note that property Number contains for each Part the value defined by operation Generate Numbering

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Create the Bill of Material Insert the Generative BOM in the

Drawing Select Window / Tile Horizontally Select the Drawing window Activate contextual menu of Sheet.1

and select Activate Sheet Select Insert / Generation / Bill of

Material Select node Mold in the

specification tree of the Product Pick in the Drawing Sheet the

location where you want to insert the BOM

Zoom in to check the content of the BOM

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Complete the Drawing Update the Title Block

Select Edit / Background Double-click the text frame of the

drawing title and change initial value xxx to Car Handle

Click OK in dialog box Text Editor Select Edit / Working Views

Global change in the definition of Section View

Select Section View B-B In its contextual menu, select Edit

Properties Uncheck option Hidden Lines Click OK to validate

The View is automatically updated

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Complete the Drawing Change Section View Profile

Double-click the profile defining Section B-B

Click icon Replace Profile Create a new profile approximately

as shown Click icon End Profile Edition

The Section View is automatically updated

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Complete the Drawing Local change in definition of

Section View In contextual menu of Section View

B-B, select Section View B-B Object / Overload properties

Dialog box Characteristics is displayed

Select the Slider The corresponding line is created in

the Characteristics dialog box Click button Edit In dialog box Editor, deactivate

option Cut in section views and activate option Represented with hidden lines

Therefore the hidden lines of this component will be displayed.

Click OK in the two dialog boxes The view is updated

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Complete the Drawing Create Balloons

Click icon Generate Balloons Arrange the position of some

overlapping balloons Close without Save

End of Step 6. Result data is : \Step6-MoldToolDrawings\End\

TwoPrintsWithInserts.CATDrawing

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V5R13 Generative Mold - Design & Manufacturing Step 7 : 2.5- & 3-Axis Manufacturing

Start Manufacturing of one Insert Start from existing Machining

Process Open file \Step7-Manufacturing\

Begin\Template_3X-roughing.CATProcess

Select Product to be machined In the PPR tree, double-click Part

Operation In dialog box Part Operation, click

icon Product or Part Select file \Step7-Manufacturing\

Begin\Product_for_demonstration.CATProduct

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Define Roughing Operations Select Part to be machined

In dialog box Part Operation, click icon Design part for simulation

Double-click the Insert in the 3D viewer

Define rough stock In dialog box Part Operation, click

icon Stock In PPR tree, double-click Part

Body of the Part named STOCK This is the rough Pad defining the

Insert, before the Insert is split with the form surfaces

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Define Roughing Operations Define a safety plane

In dialog box Part Operation, click icon Safety plane

Select plane XY in the 3D viewer In the 3D viewer, activate

contextual menu of the Safety plane Select Offset… Set Thickness = 70 mm Click OK to validate Offset

creation Click icon Left View Zoom in a little to check the

position of the Safety plane Click OK in dialog box Part

Operation to validate Part Operation

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Define Roughing Operations Define areas to be machined

Click icon Manufacturing View In dialog box Manufacturing View,

activate in contextual menu : Manufacturing View object / Sort by Machinable Features

Double-click item Part to be machined

In dialog box Zone : Areas, click the sensitive area

In the 3D viewer, first select the Insert (Part Body), then Filling Surfaces (Geometrical Set)

Double-click in the background to get dialog box Zone : Areas back

Click OK in dialog box Zone : Areas

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Define Roughing Operations Define limiting contour

In dialog box Manufacturing View, double-click item Limiting Contour Definition

In dialog box Zone : Lines, click the sensitive edge area

In toolbar Edge Selection, click icon Display option panel

In dialog box Options, make sure that Link types = Line insert

Pick successively the four corner edges of the Insert to get a result as shown

In toolbar Edge Selection, click icon Close Contour with Line to close the contour

Click OK in toolbar Edge Selection Click OK in dialog box Zone : Lines Click Close in dialog box Manufacturing

View Use Save As to store CATProcess in

another folder of your choice

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Define Roughing Operations Define computation in batch

mode Click icon Manage Batch Queue In dialog box NC Batch

Management, click icon New job In dialog box Job definition, click

icon “…” In the PPR tree, select 3-Axis

PROGRAM In dialog box Job definition, click

OK to validate

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Define Roughing Operations Start batch computation

In dialog box NC Batch Management, click button Activate

Click Yes in message panel to start execution of the batch queue

Click OK in next message panel to acknowledge it

In dialog box NC Batch Management, click OK to close it

Next machining operations (semi-finishing, finishing) can now be defined interactively while roughing operation is computed in batch

Synchronization of these operations with the result of batch computation will be done later

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Define Semi-finishing Operations Define Slope area

Click icon Machining/Slope Area Activate contextual menu of

sensitive area named Part Activate Select zones In dialog box Zone Selection, select

line Part to be machined Click right-arrow button to transfer it

to list Selected Click OK to validate selection In dialog box Machining Area,

activate option Slope Area Select tab Slope Area Select T3Ball-Nose D16 as

Reference Tool Set Lower Angle = 47 deg Set Overlap = 1 mm

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Define Semi-finishing Operations Customize predefined Slope Area

machining strategy Select tab Operations Activate field Insertion Level In the PPR tree, select operation

Roughing.3 Select area Horizontal Select Assign = Sweeping Click OK to validate

Two new operations have been automatically created in the PPR tree : ZLevel and Sweeping

The resulting sequence should be as shown.

In the last Tool Change operation, make sure that Zlevel appears before Sweeping

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Define Semi-finishing Operations Compute Tool paths

In the PPR tree, multi-select operations ZLevel and Sweeping

Click icon Tool Path Replay Both tool paths are successively

computed and displayed

Simulate Tool path In dialog box Sweeping.1, click icon

Go to start of tool path Click icon Forward replay

Simulation of the ZLevel operation begins

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Define Semi-finishing Operations Simulate Tool path

After a few seconds, click icon Display complete tool path

The simulation now runs until the end of the Sweeping operation

Click OK in dialog box Sweeping to close it

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Define Semi-finishing Operations Load additional semi-finishing

operations from existing catalog Click icon Open Catalog Click icon Browse another catalog Select file \Step7-Manufacturing\

Begin\Machining_Processes.catalog Double-click chapter 3-AXIS

OPERATIONS Double-click MachiningProcess.2

Locate new operations in the current process

In the PPR tree, select last operation (Sweeping)

Corresponding information is updated in dialog box Insert Object

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Define Semi-finishing Operations Define geometry to apply loaded

operations Click icon Manufacturing View Select Pencil Semi-Finishing

Corresponding information is updated in dialog box Insert Object

Click OK in dialog box Insert Object Click Close in dialog box Catalog

Browser Click Close in dialog box

Manufacturing View Check the PPR tree : two new

operations have been inserted (Pencil.1 and Pencil.2)

Compute tool paths Multi-select the two Pencil operations Click icon Tool Path Replay

Both Tool Paths are now computed Click OK in dialog box Pencil.2

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Define Finishing Operations Define Rework operations

Click icon Rework area In dialog box Rework Area, click

button Load from Select Sweeping.1 in the PPR tree

Sensitive area Part has turned green in dialog box Rework Area

Click tab Other in dialog box Rework Area

Set tolerance = 0.02 mm Select tab Operations Select field Insertion Level Select Pencil2 in the PPR tree Select Tool Reference = T5 Ball-

Nose D4 Click OK to validate definition Check the PPR tree : two new

operations have been inserted : Contour-driven.1 and ZLevel.2

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Define Finishing Operations Define Rework operations

In the PPR tree, double-click operation Contour-driven.1 to edit it

In dialog box Contour-driven, set Machining tolerance = 0.03 mm

Click OK to validate Similarly, edit operation Zlevel.2 to

also set Machining tolerance = 0.03 mm Compute Tool Path

Multi-select operations Contour-driven.1 and ZLevel.2

Click icon Tool Path Replay Both Tool Paths are now computed

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Define Finishing Operations Visualize computed Tool Path

In dialog box ZLevel.2, click icon Go to start of tool path

Click icon Forward replay Simulation of the Contour-driven

operation begins After a few seconds, click OK in

simulation dialog box to end the dynamic visualization

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Synchronize Result of Batch Recall batch result

Click icon Manage Batch Queue Select computed program in dialog

box NC Batch Management Click icon Synchronize a computed

job in dialog box NC Batch Management

Click Yes in message panel to get the batch-computed tool path

Status is set to Synchronized in the dialog box

Click OK to validate The Roughing operations appear

as Computed in the PPR tree

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Check Results Check Roughing operations with

video simulation Select operation Roughing.3 in the

PPR tree Click icon Tool Path Replay

Result appears instantly In dialog box Roughing.3, click

icon Video from last saved result Click icon Forward replay Move the speed cursor far right to

accelerate the simulation All three Roughing operations are

successively displayed After a while, click OK to end

dynamic visualization

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Check Results Check final result with video simulation

Select operation ZLevel.2 in the PPR tree

Click icon Tool Path Replay In dialog box ZLevel.2, click icon Mixed

Photo/Video Click icon Forward replay

The toolpath is computed very quickly

Store video result In dialog box Zlevel.2, click icon

Associate Video Result to Machining operation

Click OK in message box Manufacturing Information

Click OK to end simulation Lock Program

Activate contextual menu of 3-Axis PROGRAM

Select 3-Axis PROGRAM object / Lock Children

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Define Drilling Operations Create new Manufacturing Program

Click icon Manufacturing Program In the PPR tree, select 3-Axis

PROGRAM The new program is inserted after it

Activate Hole features Double-click Part Insert_1 in the viewer

New current workbench is Part Design In PartBody, activate contextual menu of

Remove feature ExplodedHoles This feature has automatically been

created before in workbench Mold Tooling Design thanks to function Tools/Explode Holes which has converted the original individual Remove features into features of type Hole

Select ExplodedHoles object / Activate Zoom in to briefly review the holes

There are holes coming from Cooling pipes, Screws and Ejectors

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Define Drilling Operations Go back to Manufacturing

workbench In the PPR tree, double-click 3-

Axis PROGRAM Click icon Update

You can see in the tree that all previous 3-Axis operations need to be updated, but thanks to Lock capability, the tool paths are not lost.

Run macro script to define manufacturing patterns associated to the holes

Select Tools / Macro / Macros Click button Select Select file \Step7-Manufacturing\

Begin\AllHolesPatterns.CATScript Click button Run

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Define Drilling Operations Run macro script to define

manufacturing patterns associated to the holes

Click OK in message panel requesting Part selection

Select the Insert in the 3D Viewer Click OK to acknowledge the

message displayed to confirm selection Click OK to acknowledge the

message indicating the end of execution Check the result

Click icon Manufacturing View Activate in contextual menu :

Manufacturing View object / Sort by Patterns

A Machining Pattern has been created for each type of Hole

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Define Drilling Operations Load drilling operations from

existing catalog Click icon Open Catalog Double-click chapter DRILLING

Define drilling for the first Cooling pipe

Double-click item Machining Process.1

In the PPR tree, select newly created Manufacturing program

Insertion level information is updated in dialog box Insert Object

In the Manufacturing View, select the last pattern whose name is Holes_Diam10_Blind_Counterbored

Click OK in dialog box Insert Object

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Define Drilling Operations Define drilling for the second

Cooling pipe In dialog box Catalog Browser,

double-click item Machining Process.1 In the PPR tree, select operation

Counter Boring.1 resulting from previous definition

Insertion level information is updated in dialog box Insert Object

In the Manufacturing View, select second pattern named Holes_Diam10_Blind_Counterbored

Click OK in dialog box Insert Object Click Close in dialog box catalog

Browser Click Close in dialog box

Manufacturing View

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Define Drilling Operations Compute the tool paths

In the PPR tree, multi-select all the operations defined in Manufacturing Program.2

In contextual menu, activate Compute Tool Path

Click OK in dialog box Computation mode

Click OK in message dialog box to acknowledge the warning message

All tool paths are now computed

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Define Drilling Operations Display the tool paths

In the PPR tree, multi-select the last three operations defined in Manufacturing Program.2

Click icon Tool Path Replay In dialog box Counter Boring.2, click

icon Go to start of tool path Click icon Forward replay

Simulation of operation SpotDrilling.2 begins

After a few seconds, move the speed cursor right to accelerate simulation

All operations are successively displayed

When the simulation is finished, click OK in dialog box Counter Boring.2

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Define Drilling Operations Minimize the number of tool

changes In the PPR tree, select Manufacturing

Program.2 Click icon Auto Sequence Deactivate all options except the first

one : Sort by operation type Click OK in dialog box Auto Sequence In the PPR tree, review the new

sequencing

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Define Drilling Operations Check final result with Video

simulation In the PPR tree, select last operation :

Counter Boring.2 Click icon Tool Path Replay In dialog box Counter Boring.2, click icon

Video from last saved result Click icon Forward replay After a few seconds, move the speed

cursor right to accelerate the simulation When simulation is finished, click OK in

dialog box Counter Boring.2 Close without Save

End of Step 7 Result data of Step 7 : \Step7-Manufacturing\End\CompleteMachining.CATProcess

Mold Design & Manufacturing Process(Catia)

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Transcript of Mold Design & Manufacturing Process(Catia)