Moldplus V10 7 Quick Start Guide(1)

7/24/2019 Moldplus V10 7 Quick Start Guide(1)

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Moldplus

V10.7For Mastercam X7

Quick Start Guide

M o l d p l u s S A

M a r c h 0 7 , 2 0 1 4

Moldplus Version 10.7 (10.7.0.xx)


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CONTENTS

INTRODUCTION ................................................................................................................ 1

PREREQUISITIES ............................................................................................................... 1

SOFTWARE .................................................................................................................... 1

MOLDPLUS LICENSING ....................................................................................................... 1

TO CONFIGURE THE LICENSE ........................................................................................... 1

DRAFT ANGLE ANALYSIS .................................................................................................... 5

CREATING PARTING LINES, 3D PART EDGES AND 2D PART EDGES.......................................... 8

CORE AND CAVITY SEPARATION ....................................................................................... 11

ELECTRODE MAKER ......................................................................................................... 18

DEFINITIONS AND PROCESS........................................................................................................................... 18

USING ELECTRODEMAKER 0_ELEC4.MCX-7 ...................................................................... 40

SETTING UP A JOB ........................................................................................................ 40

REVIEWING MACHINE AND GAP SETTINGS ...................................................................... 41

ADDING AN ELECTRODE ................................................................................................ 44

SELECTING THE SURFACES FOR THE ELECTRODE ............................................................. 45

ADDING THE EXTENSIONS ............................................................................................ 48

ADDING THE STOCK AND HOLDERS ................................................................................ 50

ADDING ADDITIONAL ELECTRODES ................................................................................ 54

USING CLONES TO CREATE MULITPLE ELECTRODE BURN POINTS ...................................... 67

EXPORTING ELECTRODES FOR MACHINING ..................................................................... 70

PREPARING AND PUBLISHING REPORTS .......................................................................... 71

CONCLUSION .................................................................................................................. 74


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Moldplus Quick Start Guide

1

INTRODUCTION

This document will walk you through the configuration process and introduce you to Core andCavity separation and electrode extraction and creation. The Quick Start Guide for the 5-axistoolkit can be used to learn the features of that tool. The Online Help will help you understand

more about these features.

PREREQUISITIES

Please ensure the following items are installed and configured correctly before using thisapplication guide.

SOFTWARE

Mastercam X7 for 64Bit or 32Bit.

Moldplus 10.7 for Mastercam X7-64bit or 32bit installation.

MOLDPLUS LICENSING

After Moldplus 10.7 has been installed, you will need to configure the license to enable thefeatures. Licenses are delivered as an XML file by your reseller.

As long as your maintenance is current, you can run the new features in the 5-axis toolkit.

The Moldplus STL Utilities, Fixture Design and Welding products will need new licenses to bepurchased in order to function.

New software purchases or license purchases will need to follow the routine as described toregister the licenses.

TO CONFIGURE THE LICENSE

1. Click Moldplus->About on the Mastercam menu. The About Moldplus dialog is displayed.

This dialog is also displayed when you click on any Moldplus toolbar button for the first time. Notethe actual SIM number and user type are displayed.


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2. Click Register. Browse to the location where the XML License file was saved, select the fileand click Open.


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3. If the license file is valid, the maintenance date and other information is updated. A greencheck indicates that the license is valid. Note that only the products you purchase will display.

Valid products are indicated with a green tick and invalid ones with a cross. To request a newlicense or an updated version of your current license, please contact your reseller.

If you check the box for View All, all the Moldplus product licenses available are displayed.


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Moldplus for NetHASP code registration will not be done using the above dialog. You willneed to configure the Moldplus Server Manager to configure the licenses. If the license server isnot found, the following is displayed.

Once the server is active and identified through the client, the following is displayed:


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Q U I C K S T A R T G U I D E

This guide will walk you through:Draft Analysis,parting line creation,Solid Sep (core and cavity

separation) andelectrode extraction,creation and report generation in about 10 minutes or less.

The files referred to here can be found in the \SHARED MCAMX7\MCX\Moldplus_Examples_MMfolder.

DRAFT ANGLE ANALYSIS

Moldplus offers very powerful tools for analyzing parts for undercut surfaces, etc. With 1 click of

the mouse, you should be able to analyze the part and automatically trim the undercut surfacesand place them in different colors and levels. This feature alone will eliminate the need tomachine prototypes before realizing that the mold cannot be pulled apart because there are

undercut surfaces. To do this:

Step 1: Load the file: Load the so l i d _ se p _ e l e ct r o d e s _ m m . m cx - 7 file.

You can analyze this part in the Topview and determine if there any undercuts or not.With this part, it is pretty obvious that you will not have any undercuts but it is good toverify the draft analysis before starting the separation.


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Step 2: Start draft angle analysis: Launch Moldplus Draft

Angle Analysis from the Moldplus Toolbar . The Draft

angles dialog is displayed.

Step 3: Review the settings:ClickSettings to display the Draft

Angle settings dialog.

Change the values as shown.

The Abovevalue defines thepositive angles with respect to thecurrent CPlane that are positive.Surfaces in the part with this anglewill be colored green and moved tothe layer shown.

Surfaces with angles between 3 and0 degrees as colored yellow.

Undercut surfaces are colored

green.

Click OK to close the dialog.


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Step 4: Analyzing draft angles:Verify the CPlane is set to Topand click Do it.

You will notice that all geometry betweenand above 3 degrees are marked in green. Theyellow surfaces indicate the 0 to 3 degree range. In this part, they can be machined aspart of the cavity. The red surfaces are all marked as undercut since they lie beneath thecavity faces. All the surfaces considered as an undercut here can be considered as core

geometry.

Step 5: Verification of results:To see that the surfaces are trimmed and moved todifferent levels, press Alt+Zor click Levelat the bottom of the Mastercam graphicswindow to display the Mastercam Level Manager.

Disable Level 1 (the surface geometry level). Click OK. Only the yellow and red surfaceswill be left. You can also disable the Level 3 to see only the red surfaces if you prefer.

An overall analysis at this stage tells you that there are no undercuts in this part, a coreand cavity can be created and machined and that there is no need to have any slides or

lifter geometries to manufacture this part. Only electrodes are needed to burn the cavityribs.

Step 6:

Restore the surfaces:Undo the Draft Angle analysis by clicking Undo/Redo.This will restore all the surfaces to the original levels, ready for parting line creation.

This completes Draft Angle analysis.


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CREATING PARTING LINES, 3D PART EDGES AND 2D PART EDGES

Moldplus allows the quick creation of Parting Lines, 3D part edges and 2d projected part edges.All these are helpful to complete a mold design (for example, creating Run-offs to mold edges).

You can easily create the 3D parting edges for molds. This is useful where you need these

external edges to create run-offs to the mold edges using manual run-off creation methods. Sincewe analyzed the part and found no undercuts, we know that the parting lines for this part are theexternal edges of the part.

Step 1: Start 3D part edges:Click 3D Edges on theMoldplustoolbar. The Moldplus: Surface Edgesdialog isdisplayed.

Step 2: Reviewing settings:

Click Settings to open theSettingsdialog. Review thesettings and verify they are setcorrectly.


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Step 3: Create the 3d part edges: Click Part Edgesto create the edges.

N o t e: There will probably be additional edges created where the software identifies gapsbetween the faces. This feature will quickly tell you if there are inconsistencies/ gaps

between surfaces and is useful to check the consistency of a surface model. In many casesthe gaps may be irrelevant due to a bad conversion of a solid to a surface model or loosetolerances while importing the model.

Step 4: Delete internal edges: Delete the internal edges using the Mastercam tools.

The exterior edges can be then be used to create the run-off surfaces easily using the

Moldplus Partsurffunctions.


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Step 5: Create 2d projected edges from the part: From the Mastercam menu, clickMoldplus->Moldplus1to display the Moldplus dialog. Click Edgesthen click on 2DProject, Settings.

The projected edges can automatically be created as Arcs and lines rather than as splinedata.

Ensure the settings are as shown:

Step 6: Change the Mastercam system color to 1.Click Part Edgesto create lines and arcsrepresenting the part edges.

Using this quick contouring or pocketing can be done, or whatever else you wish to do.

Step 7: Click Undoto remove the 2D curves.

This completes the creation of the parting lines, 3D edges and 2D projected edges. You canalso do those for single surfaces or get all the edges of all the surfaces if desired.


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CORE AND CAVITY SEPARATION

Core and cavity separation using Moldplus is a very powerful tool that automates the process ofidentifying core and cavity geometry. This means what would take hours manually can be done ina few clicks.

Step 1: Load the file:Continue with the same part orreload the SOLID_SEP_ELECTRODES_MM.mcx file.

You can use Screen->Statistics to verify that there are 27

surfaces and 273 trimmed surfaces that need to be

separated.

Step 2: Start SolidSep: From the Moldplus toolbar, click

SolidSep to display the Core and Cavity Separation

dialog.


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Step 3: Review Settings: Click Settings and verify the settings are as shown below.

The Settings dialog allows you to organize the splitting process by colors and levels foreasy identification and manipulation.

As normal practice, the cavity (the external shell of the mold) would be what is considered

here as CP Z+ (Construction Plane Z Positive) and the core (the internal shell of themold) would be CP Z-.

When the Open Mold option is selected, , the CP Z+ geometry will be translated by the

distance specified in CP translation heights above the original location, set to color 10and moved to Level 2. The CP Z- surfaces will stay in the current location and have itsproperties changed to Level 3 and color 4. Any straddle (surfaces that straddle the parting

line of the geometry) or vertical or unknown surfaces will be moved to half the distance

(75 mm in this case) to allow the user to decide which side they belong to and markedwith the corresponding colors and moved to the set levels.

If you are starting with a solid model directly, Moldplus will convert the Solids to a surfacemodel first and move the solid to the level specified in Converted Solid level.

Upon reviewing the settings, click Doneto close the dialog.


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Step 4: Performing the operation: Click Do Itto perform the separation.

You are prompted with the dialog that gives the user a warning that the properties of thesurfaces willbe changed. This is a friendly warning! Click OK to continue.

The separation takes place within a few seconds and the following will the presented.

The surfaces are now split for core and cavity and displayed according to the settings. Youwill notice that there are no verticals, straddles or unknown surfaces (would normally bedisplayed in the middle). From the main Core and Cavity menu, you can easily movesurfaces between core and cavity by simply clicking on them. Since this was a perfect

split, we dont have to do anything more to this part.

Step 5: Restore surfaces to original heights: Click on Open/Close to return all the

surfaces to the original Z heights. You are done with the separation part.


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We will now create parting surfaces to the mold edge in 1 click. We can use the pre-sketchedboundary as the mold insert boundary and use the CP Z- or core geometry to create them.Remember that only one side should be active (either the Core or the Cavity side only).

Step 6: Set the Mastercam levels: Click Levelon the Mastercam status bar or pressAlt+Zto open the Mastercam Level Manager.

Disable Level 2 (the CP Z+ level) to leave only the CP Z- surfaces visible.


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Step 7: Start Partsurf: On the Moldplus toolbar, click Auto

Partsurf to display the PartSurfdialog.

Step 8: Set stock limits: Click Stock Limits. The Mastercam Chaining dialog is displayed.Click on any of the entities forming the stock boundaries to select the chain.


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Step 9: Create the surfaces: Click Create1. This will create the mold edges extensions.The following should be the result.

With the run-off created, you will need to create the shut-offs for the core and cavity.

We will create the shut-off surfaces using the Moldplus Supertrim functions. Note that thesefunctions are part of the Moldplus Supertrim bundle.

Step 10: Close holes using Supertrim: Click Supertrim1

on the Moldplus toolbar. This displays the SuperTrim

dialog.

Click Closed Holeand select the Fill Holeoption.


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Click the holes to be filled near any edge as shown in the figure.

The hole is filled automatically.

Continue to click the other holes to fill them up.

Press Esc multiple times to exit the dialog.

You can complete the separation and the parting surfaces creation in this manner. In a matter ofminutes, you have completed the core and cavity separation, mold run-off creation and addedshut-off surfaces - powerful time savings tools that could help see an instant return ininvestment!


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ELECTRODE MAKER

This section will cover Moldplus Electrode Maker. There is far more automation and user controlbuilt in to isolating electrodes, inserting electrode stocks, preparing them for machining withproper extensions for strength and proper burning and finally generating textual and visual HTML

reports. The steps outlined will allow you to review Electrode Maker in a matter of few minuteswithout having to understand all the details of the Settings.

DEFINITIONS AND PROCESS

We will be referring to geometry here as:

Reference geometry the selected geometry from the part to create electrodes for.

Stock Electrode the inserted electrode stock usually wireframe geometry along with a holder

attachment.

Electrode Holder the standard electrode holders from 3R or EROWA.

Guard plane the electrode extensions will terminate at this Z height. This will result in themachine-able area of the electrode.

Step 1: Load the file: Continue with the same file that you split the core and cavity from.

You will notice there are several ribs and inserts to burn into the core. We will create a fewelectrodes from this part a rough electrode to burn multiple ribs and a few finish

electrodes.


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Step 2: Start Electrode Maker: Start ElectrodeMaker byclicking ElectrodeMaker V10on the Moldplus toolbar. Thiswill display the ElectrodeMaker dialog.

Step 3: Review and change settings: Click Settings to review and change the settingsfor the electrodes created on this part.

Click Part Configuration in the tree and change the settings as shown below:


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Click Defaultto set the Electrodes output folderto set the folder based on the path ofthe part

Step 4: Review and change the Machine Settings: Machine settings control how the

ElectrodeMaker outputs EDM machining code for the created electrodes.

Click Machines in the tree and

click Newto create a newmachine profile.

Enter a name for the machine

profile and click OK.

Enter the machine name

Click to show the Select Postprocessor Filedialog and select the file \shared

Mcamx6\mill\Posts\MPE_EDM_MACH_X6.PST as shown below.

Change the other settings as shown below:


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Step 5: ReviewtheGap Configuration:Clicking Gapsin the tree. Make sure the settingsare the same as shown below:

Note: The gaps configured in the Gaps settings page are used only for documentation. ElectrodeMaker does not yet create surfaces that are offset from the originals by the gaps set here.

Click OKto save the settings and exit the settings dialog. If the folder does not exist, it isautomatically created.


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Step 6: LaunchtheMastercamLevel Manager. Turn off alllevels except for Level 3.

Step 7: Create new electrode:Right-clickon the electrode list.

From the menu, select NewElectrode.

The electrode properties dialog isdisplayed.

Click OKto create the electrode.

Next, we will select the surfaces that make up the electrode. This can be done via theSurfaces Selectiondialog that replaces the Electrode List


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Step 8: Select electrode surfaces:This dialog is shown on clicking OKin step 7.

Click the Electrode Surfacesbox to activate it.

Hold down the Shift key and select the surface shown.

This will select all the surfaces of the rib automatically.


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Select the other two ribs as shown. Rememberto keep the Shift key pressed when selectingthe surfaces.

Select the option Show selectedsurfaces onlyto verify that all the ribs

are selected.

Once you are satisfied with theselection, unselect the option and clickAccept Selectionto close the dialog.


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Step 9: Add additional surfaces to theelectrode: The following dialog is displayed onclicking Accept Selectionin the previous step.

Note that the numbers of surfaces are shownagainst each selection.

From here, we will add additional surfaces tocomplete the electrode.


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Step 10: Create tangent extensions:Double-clickon First Tangent.Thiswill display the Extension propertiesdialog.

Select the Tangent Offsetoption.

Enter 10for the Edge Offset.

Click Previewto see a preview of the extension surfaces.

Click OKto accept the surfaces.

Next, we will add draft to the extensions to make the electrode stronger.


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Step 11: Create draft: Double-clickDraft. Change the settings in theExtension Propertiesdialog asshown here:

Click Previewto verify the draft is correct and

click OKto create the surfaces.


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Step 12: Add stock and electrode holder: Double-clickon Raw Stock.This will displaythe Stock and Holder Definitiondialog.

Under the Holder directory, click the listbox and select 3R_54X54X30mm.MCX.


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Next, we will change the stockparameters to ensure the electroderawstock is calculated correctly.

Change the value of Z stockto 2.

Most electrodes will also have chamfers for ease of setup during machining. These can be

created automatically.

Change the options as shown to the right:

Face XY defines the distance from themachined sides of the electrode to the raw

stock.

Stock XYdefines the distance from addedfrom the extents of the electrode surfaces to

the machines side of the electrode.

Under Stock definition, click Rect. This will

recalculate all the electrode dimensions tosuit the dimensions entered for the stockvalues.

The preview will update to show the correct

stock sizes. Note the chamfers are shown aswell.

Once you are satisfied with the electrode stockand holder, click OKto apply the stock andholder.


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Step 13: Complete the first electrode: OnclickingApply in the previous step, the Stockand Holder Definitionwill be closed andElectrode Edit dialog is displayed.

Click End Editto return to the main ElectrodeMaker dialog.

We will now create a finish electrode for one of the ribs. The other ribs can be finished using the

same electrode.


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Step 14: Add the second electrode: Add another electrode by right-clicking on an emptyarea of the electrode list and selecting New Elecfrom the menu.

Click OKto add thenew electrode to thelist.


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Step 15: Select surfaces for the electrode: When thesurfaceselection dialog is shown, hold down shit andselect the surface shown:

Select the Show selected surfaces onlycheckbox to verify that only the rib has been selected.

Click Accept Selectionto display the extensions dialog.

Create the first extension: Double-click First Tangentto create the tangent. Create the tangent surfaces usingthe Tangent Offset option and an Edge Offsetof 10mm.

This edge offset is too large for a finishing electrode.

You can also delete the extensions by

right-clicking the item in the list andselecting Delete this level from themenu.


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Double-click First Tangent to show the ExtensionProperties dialog again. This allows the extensions to beedited easily.

Change the Edge Offsetto 3mm and click to update theextension.

Step 16: Create draft surfaces: Double-click Drafttocreate the draft with an angleof 0degrees and a

distanceof 10mm.

Click OKto create the draft and close the dialog.

Step 17: Add raw stock and holder: Double-click Raw stockto start the Stock andHolder Definitiondialog.

Under Stock Definition,note the size of theraw stock displayed. This will allow us toselect the appropriate holder for thiselectrode.

Select the holder 3R_20mm.MCX.


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Change Face XYto 2mm, Stock XY

to 3 mm and Chamferto 1 mm.

Under Stock definition, click Rectto recalculate the stock sizeand show the preview.

Note the preview shows the holder lies outside stock.

We will rotate the holder to correct this.

Under Rotation, unselect the Same as stockoption. This will

ensure that only the holder will be rotated.

Click +90under Angle Holder to rotate the holder. ClickApplyto update the preview.

Note the holder is now correctly aligned tothe electrode.

Click OKto create the holder and display

the surfaces selection dialog.

Click End Editto return to the main Electrode Maker dialog.


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Note that the second electrode is hidden by the roughing electrode.

Electrodes can be displayed or hidden by using the check box againstthe electrode name OR by having the Selection Auto option checkedin the right click menu. Then the electrode is highlighted when youclick on the list.

You can also select the box to display the electrode and unselect it to hide it.

Clicking on an electrode will temporarily make it visible.

Step 18: Hide the first electrode: Hide Elec-1by clearing the check box.


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To create shop floor documentation for the electrodes we have just created, we will use theMoldplus XML report generation function. This report has all the information needed by theshop floor to set up and machine the part, including images of the electrodes and their burnlocation.

Step 19:

Prepare and display the XML report:From the mainElectrode Maker dialog, click Exportand select XML reportfrom the menu.

The XML Reportdialog is displayed.

Click Capture checkedto capture images of all the electrodes. This captures images ofthe electrodes and the part. The images are displayed under Image.


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You can verify the images that are captured for each electrode by selecting it in the list atthe left of the dialog.

If you wish to change any settings and recapture the images, select the electrode in thelist and click Capture selected.

The following image shows Elec-1captured using shading.

Once you are satisfied with the images, click Make XMLto generate the report and view itusing your Internet Browser.


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Click Closeto close the XML Report dialog.


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To machine the electrodes, they will have to be saved to individual MCX files. This can beachieved easily using Electrode Makerss Export function.

Step 20: Export the electrodes for machining:Click Exportand select Elecs to folderfrom the menu.

This will display the Elecs to folderdialog.

Click Defaultto set the output folderto a folder that is based on the name of thecurrent part.

Click the Export Levels list box and select the option Surf+Ext: Surf Holder: nochange option. This will ensure that all the surfaces and extensions are one level and theholder levels are unchanged from the part.

Click the Translationlist box and select the Top Base (Pt1) to originoption toautomatically translate the electrodes burn point to the origin. Select Flipto ensure theelectrodes are oriented correctly for machining.

Click OKto create the electrodes.

This concludes the review of the process of splitting Core and Cavity and creating 2 electrodes onthe same file.

We will review the Electrode Maker on another example file now and review other options withinthe Electrode Maker tool.


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USING ELECTRODEMAKER 0_ELEC4.MCX-7

Using ElectrodeMaker to create electrodes has the following workflow:

1. Setting up a job

2. Reviewing and changing machine and gap settings.

3. Adding an electrode

4.

Selecting the faces for the electrode

5. Adding the extensions

6. Selecting and adding the stock and the holder

7. Exporting the electrodes to a different file for machining

8.

Preparing and publishing reports

For multiple electrodes, steps 3-6 would be repeated as often as necessary.

SETTING UP A JOB

Step 1: Load the 0_ELEC4.MCX-7file from the Examples

folder.

Start ElectrodeMaker by selecting Moldplus->ElectrodeMaker->ElectrodeMaker V10on the

Mastercam menu or clicking the icon on the Moldplustoolbar.

The ElectrodeMakerdialog is displayed.


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REVIEWING MACHINE AND GAP SETTINGS

Step 2: Click Settings to review and change the settings for the electrodes created on thispart.

General Setup (System) should be set as follows:

Click Part Configuration in the tree and change the settings as shown below:


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Step 3: Review and change the Machine Settings. Machine settings control how theElectrodeMaker outputs EDM machining code for the created electrodes.

Click Machines in the tree and select the machine profile Fanucand settings if notalready selected as shown below.

Ensure the post processor is selected as follows and the Burn pointlocation set toBottom of Chamfer (PT3)


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Step 4: Review the Gap Configurationby clicking Gapsin the tree. Make sure thesettings are the same as shown below:

Note: The gaps configured in the Gaps settings page are used only for documentation.ElectrodeMaker does not yet create surfaces that are offset from the originals by the gaps sethere.


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ADDING AN ELECTRODE

Step 5: To add an electrode,right-click on the list of

electrodes.

From the menu, select Newelec.

Step 6: TheElectrodeProperties

dialog isdisplayed. Theelectrodeprefix is

named withthe settingsdefined in Step2.

Click OKtoadd theelectrode.


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SELECTING THE SURFACES FOR THE ELECTRODE

Once the electrode has been added, the next step is selecting the surfaces on the part tobe burned with the electrode.

ElectrodeMaker allows surface selection via one three methods:

1. Manual selection

2. Step by step selection

3.

Automatic selection

4. Using Mastercam selection tools

First, use the automatic selection to select the surfaces.

Step 7: On clicking OKin step 6, the following

dialog is displayed.

Activate the Electrode surfaces selection box byclicking in the box. An active selection box is

highlighted.


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Step 8: Hold down the Shiftkeyand select this surface.

All the surfaces making up the ribare selected and highlighted.

The selection box will list the surfaces and listthe total number of surfaces selected.

Step 9: Verify the correct surfaces areselected by selecting the Show

selected surfaces onlycheck box.This will show only the selectedsurfaces.


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Step 10: Click Accept selectionto complete theselection.

The part is displayed again and the ElectrodeMakerdialog changes to Edit Electrode mode.

The dialog shows the various types of surfacesmaking up the electrode and lists the levels thesurfaces are on and the number of surfaces of

each type.

You can manage all the surface extensions neededto manufacture this electrode (tangent, draftextension, etc.) and build the stock and assign a

holder.

Once the electrode is built, you can also check forcollision detection with the part.


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ADDING THE EXTENSIONS

Once the electrode surfaces are created, they need to be extended beyond the burn depth toprevent unwanted burns on the part. Extensions can be created automatically in one of many

different ways in ElectrodeMaker.

Step 11: Double-clickFirst Tangentinthe ElectrodeMaker dialog to startadding the first extension.

This will launch the ExtensionPropertiesdialog.

Change the options as shown in thefigure.

Step 12: Click Preview to see apreview of the extensions.

If the extensions are too short,change Edge offsetand click

Previewagain.

Once the extensions appearsatisfactory, click OK to createthe extensions and close theElectrode Propertiesdialog.


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Step 13: Review the ElectrodeMakerdialog. Note thatthe number of surfaces is now listed against FirstTangent.

Next, drafted extensions will be added for theelectrode, so that it can be machined easily.

Step 14: Double-click Draftto startadding the draft surfaces.

This will launch the Extensionproperties dialog for the draft.

Change the settings as shown in thefigure and click Preview.

Click OKto create the draft surfaces.


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ADDING THE STOCK AND HOLDERS

The next step is to add the stock from which the electrode will be machined. ElectrodeMaker can

automatically calculate the size needed for the raw stock. In addition, a holder can be selectedfrom a list of standard holders.

Step 15: Double-click Raw stock. This will show the Stock and Holder definition dialog.


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Step 16: Click the

button in the Holder Parametersgroup and select 3R_20MM.MCX fromthe list.

This will change the stock size to the

nearest size that will fit the selectedsurfaces.

Step 17:

Change the parameters asshown in the figure.


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Step 18: Click Rectunder StockDefinition.

This will update the size of the stock andchange all the parameters of the burn

points.

Also, a preview of the electrode and holder is shown.

The top surface of the stock is hidden so that the chamfer

locations and stock sizes can be verified.

Step 19: Click OKto create the electrode.

The electrode is completed and displayed.


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The electrode can be checked for collisions from the same dialog.

Step 20: Click On/Off. button.

The button changes color to indicate it is active, andthe slider is now enabled.

Move the slider to the right to move the

electrode.

Click On/Offagain to clear the animation.

In this case, the electrode created does nothave any collisions with the part.

Congratulations! The first electrode iscreated.

Click End Edit to close the Edit Electrodedialog and go back to the Electrodes list.


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ADDING ADDITIONAL ELECTRODES

To complete the job, more electrodes are needed to burn other profiles in the part. The process

for adding these electrodes will be the same as the previous electrode.

Step 21:

Add a new electrode byright-clickingon theelectrode list and selectingNew Elec.

Click OKin the ElectrodePropertiesdialog to createthe electrode.

Step 22: Click the Electrode Surfaces box.

Hold down Shiftand click the surface

shown.


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Step 23: Hold down Shiftand clickthe surface shown.

Select Show selected surfaces toverify that these surfaces are

selected.

Click Accept Selectionto close theselection dialog.


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Step 24: Double-clickFirst Tangentinthe ElectrodeMaker dialog to startadding the first extension.

This will launch the Extension

Propertiesdialog.

Change the options as shown in the

figure.

Click Previewto verify that theextensions are correct and click Oktocreate the extensions and return to theElectrodeMaker dialog.


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Step 25: Double-click Draftto start

adding the draft surfaces.

Change the parameters as shown in

the figure and click Preview.Notethat the draft surfaces are notoptimal since they intersect.

Click Cancelto remove the preview.

The extensions will first need to bemodified to ensure continuity beforewe can create the draft. This can bedone using the Moldplus tools.


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Step 26: Right-click First draftin and selectSet as main levelfrom the menu.

This will ensure that the surfaces that will becreated using the Moldplus tools will becreated on the same level as the first draft

surfaces.

Click End Editto close the Electrode Edit

dialog and return to the Electrodes List.

Step 27: Unselect Part to hide the part this makes iteasier to create the extensions.

Uncheck Elec-1as well so that only Elec-2 isdisplayed when you close the dialog.

Click Closeto close the ElectrodeMaker.

The Moldplus Junction Surface function can be used to create the extensions between thesurfaces.

Step 28: Click JunctSurf on the Moldplus

toolbar. This will launch the Moldplus JunctionSurfacesdialog.

Make sure the settings are as shown in the

figure.

To toggle a setting, click the button.


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Step 29: Select the edges, in order, as shown in the figure. The junction surface is createdas shown in the figure on the right on the external shape.

Step 30: Select the edges as shown in the figure. The second junction surface is created as

shown on the inner shape.

Rotate the part view to show theunderside of the surfaces. Note the gap

that has to be closed.

1

2

1

2


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Step 31: Change the setting TangMode to N by clicking thebutton to toggle the setting.

Select the two edges as shown in the figure. The gap is bridged as shown in the figure onthe right.

Close the Junction Surface dialog by pressing Esc.

Step 32: Start the Electrode Maker again.

Display the part by selecting Part.

Edit Elec-2either by double-clickingor right-clicking and selecting Elect Editfrom themenu.

1

2


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Step 33: Double-click Second tangent

to display the Extension propertiesdialog.

Change the parameters as shown inthe figure.

Click Okto create the extensions.

Note the extensions are also

created for the surfacescreated via Junction Surface.


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Step 34: Double-click Draftto startadding the draft surfaces.

Create the Draft with theparameters shown in the figure.

The draft created is much smoother andprecise this time.


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Step 35: Double-click Raw stock. This will show the Stock and Holder definition dialog.

Select the 3R_50MM.MCX Holder.

Change the parameters shown inthe figure for the FaceXY value.

Click Squareunder Stock Definition to

recalculate the stock size.


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Note the stock is added in at an angle sinceAuto Angle Fitunder Rotation is active.

You will notice that the values forStk_Base, Stk_Chfand the Burn Point3are not rounded.

If we want to round the values and adjust the

Z height, we can use a height adjustment

option. Choose the Rounding PT3[Z] usingZ Stock and AddZ.

The following values are adjusted and give usa rounded burn pointvalue in Z! The StockBase and StockChamfer are integervalues. The difference

is added to theAdd_Z and Z stockvalues.


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If you want the PT[3] (burn point

location) rounded to an integer value andto eliminate the Add Z value (it leaves agap in the electrode extension by the setvalue), you can re-adjust the Draft

extension value to make up for thisdifference. Click on OK and launch theDraftextension again. Set theparameters as follows:

Return to the Raw

Stockdialog. Youwill notice thevalues changed forAdd_Zand BurnPoint 3and the Z

height

You can manipulate the values using the different rounding methods and get your desiredresults for the electrode extensions and stock size.

Click Okto create the electrode.


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Click End Edit to return to the ElectrodeMaker dialog.

The figure shows the part with the completed electrodes.


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USING CLONES TO CREATE MULITPLE ELECTRODE BURN POINTS

Often, parts have the same profile in multiple locations. Instead of creating multiple electrodes ateach location, the ElectrodeMaker clone feature can be used to copy the electrodes at each

location.

The geometry for each electrode is not copied instead the burn locations are computed andwritten to the reports.

Step 36: Right-click Elec1in theElectrodes list and selectEdit/Create Clone from the

menu.

The part is automatically placed in the Top Gview and the other electrodes are hidden.


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Step 37: Right-Click on the clones list and selectNew Clone.

This will create a new clone.

Step 38: Press Shift and click near theinsertion point for Elec-1. Drag themouse note the preview displayedfor the clone in yellow.

Note also the dx,dyand dz valuesunder Offsetare updated.

These values can be used toprecisely position the clone.

Enter the values as shown and click

Apply.

Note the electrode clone is now positionedcorrectly.


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Step 39: Click End Edit to return to the main ElectrodeMaker dialog.

Note the electrode is still displayed.

Switch to the ISOGview and to Shaded displayed mode.

Check the box for Clones to display the Clones as asub-list of the main electrode.in the list and the cloneis no longer hidden.

Note the clone is now displayed as shown.


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EXPORTING ELECTRODES FOR MACHINING

All the electrodes are saved in the same MCX file as the part. To machine them and create thetoolpaths, the electrodes have to be saved to individual MCX files.

ElectrodeMaker can export these electrodes automatically.

Step 40: In the ElectrodeMaker dialog,click Export and select Elecs to folderfrom the menu.

The Elecs tofolder dialog is

displayed.

Make sure the

settings are asdisplayed.

If the outputfolder is

different, click

Defaultto setit to the correctfolder.

Click Okto export the electrodes to individualMCX folder. The file names are the same as

the electrode names.

If any of the electrode files are opened, notethat the electrode orientation has beenflipped for easier machining.


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PREPARING AND PUBLISHING REPORTS

ElectrodeMaker can automatically generate reports for shop floor documentation. The reports are

generated in XML folder and can be opened with any internet browser.

Step 41: In the ElectrodeMaker dialog, clickExport and select XML report from themenu.

The XML Report dialog is displayed.

If any of the images are not displayed, click Check all and Capture checked to capturethe images.


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Step 42: Ensure that the style sheet Style1.xsl is selected under XSL Settings.

Click the browse button and locate the file, if a different XSL file is selected.

Click Make XMLto create the report and open it in the browser.

Note that the clone for Elec-1 has its burn location listed in the report below the gapvalues.

Click Close to close the XML Reportdialog and return to ElectrodeMaker.


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Step 43: Click Export and select To machinefromthe menu.

The Electrode Post Processing dialog is displayed.

Review the settings and click Create Mach. Reportto generate the report.


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The report is generated and opened in the default Mastercam editor.

This completes the process for making some electrodes using ElectrodeMaker.

More electrodes can be added to complete all the operations in the part using similarmethods to those outlined in this guide.

For more information on the advanced functions and options available in ElectrodeMaker,please consult the help file and application guides.

CONCLUSION

This concludes the Moldplus Quick Start Guide! For any further details on the product, pleaserefer to the on-line help.

Moldplus V10 7 Quick Start Guide(1)

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