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Spli tWorks 2009 SP0User Guide and Tutorial

March 2009

PROPRIETARY RIGHTS NOTICE: All rights reserved. No part of this material may beproduced or transmitted in any form or by any means, electronic, mechanical, or otherwise,

including photocopying and recording or in connection with any information storage or retrieval

system, without the permission in writing from R&B.

The information in this document is subject change without notice and should not be construed as

a commitment by R&B.

R&B assumes no responsibility for any errors that may appear in this document.

The software described in this document is furnished under license and may be used or copiedonly in accordance with the terms of such a license.

Copyright 2000-2009 by R&BAll rights reserved

R&B LTD.

Kanyon HadrachimYokneam 20692

ISRAEL


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0 Table of Contents

Chapter 1 1 Introduction 1-1

1.1 System Requirements ............................................................................1-4

1.2 Installing SplitWorks...............................................................................1-5

1.3 Licensing SplitWorks..............................................................................1-6

Chapter 2 2 User Guide 2-1

2.1 Split Part ..........................................................................................2-2

2.2 SplitWorks Property Page .....................................2-6

2.3 Plug Hole(s) ....................................................................................2-15

2.4 Loft ..................................................................................................2-17

2.5 Create Solid Insert ..........................................................................2-20

2.6 Clean ...............................................................................................2-25

2.7 Chain Edges...........................................................................................2-26

2.8 SplitWorks Delete...................................................................................2-272.9 Planar Surface........................................................................................2-28

2.10Create a User Insert Blank Library.........................................................2-29

Chapter 3 3 Tutor ial 1 3-1

3.1 Core and Cavity Creation.......................................................................3-2

3.2 Side Cores..............................................................................................3-18

3.3 Propagation of part changes to the core cavity and side cores. ............3-21

3.4 Cavity Pins..............................................................................................3-25


4.1 Parting Line on Both Direction Faces.....................................................4-2

4.2 Parting Surface.......................................................................................4-8

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5.1 Organizing Data .....................................................................................5-2

5.1.1 Read in part data .............................................................................5-2

5.2 Modify Part for Manufacture ...................................................................5-45.2.1 Silhouette parting line......................................................................5-55.2.2 Complete the Parting line................................................................5-75.2.3 Create Surface ............................................................................... 5-22

5.3 Cavity and Core Inserts..........................................................................5-24

5.3.1 Solid Cavity and Core....................................................................5-32

5.4 Side Cores..............................................................................................5-34

5.4.1 Side Core 1 ....................................................................................5-345.4.2 Side Core 2 ....................................................................................5-395.4.3 Extract side cores from the core....................................................5-41

5.5 Check Part..............................................................................................5-42


6.1 Propagation of modifications through SolidWorks .................................6-2

6.1.1 Creating the inserts..........................................................................6-26.1.2 Correcting the original part ............................................................6-5

6.2 Changes in an IGES file .........................................................................6-11

6.2.1 Creating the inserts........................................................................6-116.2.2 Reading in a modified IGES file ....................................................6-16

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11 Introduction

SplitWorks is an advanced splitting environment, using revolutionarytechnology, to automate the process of core and cavity separation.

The splitting process begins with the

Split Part menu. This menu displays a color preview on a part (and optionallythe parting lines as well), of the potential core, cavity, zero draft angle surfacesand surfaces, which belong to both the core and the cavity, according to asplitting direction. The part may be a solid created in SolidWorks, read inthrough IGES, DXF etc. or even non-solid geometry. Modifying the splitdirection, by clicking on a plane, planar face or edge, dynamically updates the

preview. Undercuts and no draft angle surfaces analyzed at this stage allowyou to determine the best splitting direction.

Faces, which belong to both the core and the cavity (called Both directionfaces), are automatically displayed in the silhouette dialogue. These faceshave their own silhouette angle so that you can judge whether they reallybelong to the core or the cavity especially after creating a silhouette.SplitWorks allows you to choose the faces on which to preview the potentialsplit lines at the same time updating the display to reflect the changes.

No Draft faces that are adjacent to Core and No Draft faces only, are called No

Draft Core faces, and No Draft faces that are adjacent to Cavity and No Draftfaces only, are called No Draft Cavity faces. The user may then decidewhether to create these two groups or to add these faces to the Core or theCavity definitions respectively.

Each category can be hidden from the preview and/or its color map changed.


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The geometry is then exploded into four or six groups (ifNo Draft Cavity/Core

is requested) of faces under a special property page tab .

Core

CavityBoth Directions

No Draft

No Draft Cavity

No Draft Core

A group containing open and closed parting lines is also created.

The groups of faces (and parting lines) are actually pointers to the originalsolid part and not duplicated entities.

Modifications to the solid part automatically (default) or manually categorizethe new faces into the existing groups.

SplitWorks provides the following tools under the SplitWorks tab.

1. Drag faces from group to group.

2. Create new groups.

3. Show/Hide groups or individual faces.

4. Modify group face colors.

5. Show/Hide Open /Closed Parting lines.

6. Rebuild or (Automatically Rebuild) parting lines.

7. Create/Update Surface from a group of faces.

8. Split no draft faces.

9. Island Analysis to browse through disconnected parts of the samegroup and select them allowing you to move them to differentgroups etc.

10. Create edges composite curves from open or closed parting lines.

11. Create a new part from a group of faces.

12. Import an external file to be used as core or cavity surface.

13. Zoom to a single face or parting line.

SplitWorks has menus to:

1. Split the part

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1-4SplitWorks 2009

1.1 System RequirementsSplitWorks is fully integrated under the SolidWorks environment thus systemrequirements are similar to those of SolidWorks.

HardwareSince SplitWorks creates relatively large assemblies we recommend using theoptimum hardware recommendations from SolidWorks.

Operating System

Windows XP/Vista 32it or 64bit.

Networks

Windows XP/Vista.

Required Software

MoldWorks current version is MoldWorks 2009.

SolidWorks current version is SolidWorks 2009.

Adobe Acrobat Reader.

Licensing

MoldWorks is protected using a software license system FLEXlm (FLEXnetPublisher Licensing Module), which allows both an individual standalonelicense (locked to a workstation) and floating licensing (across a network)without the need for a dongle.


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1-5SplitWorks 2009

1.2 Installing SplitWorksA user must have administrator privileges to install SplitWorks.

Make sure that SolidWorks is not running during the installation.

The SplitWorks installation can be initiated from a CD or from an executablefile downloaded from the R&B web site (www.RnBUSA.com)

Once the installation is completed, logon as the user and activate SolidWorks.You may have to add SplitWorks to the SolidWorks add-ins using theSolidWorks > Tools > Add-ins menu.
http://www.rnbusa.com/http://www.rnbusa.com/


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1.3 Licensing SplitWorksR&B uses the FLEXlm (FLEXnet Publisher Licensing Module) licensemanager for all of its licensed products. This is a separate module allowing

licensing on a node locked or floating (server/client) basis.If this is an initial installation (i.e. the current SplitWorks products have neverbeen installed on this workstation) a message box will pop up which allows youto make a license request by clicking on the Registerbutton. A license requestcan also be made at any time through the SplitWorks > License Registrationmenu or from the Start > R&B > License> R&B License Manager. Refer to theR&B License Guide for details on how to fill out and send the license request.If you have no license or the license has less then 30 days left then a similarmessage box will appear as follows:

.

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22 User Guide


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2.1 Split Part

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The SplitWorks >Split Part menu orrelevant icon opens the Split Part dialogue box.

This menu is active in the Part documentenvironment.

Two tabs appear:

Analysis (default). Input split directiondata and create silhouette.

Legend. Choose output coloring as wellas options regarding face classification.

The Analysis tab has 2 parts to it:

Input

Direction:

Select a plane, planar face or edge. Thenormal to the plane or the face becomes thesplit direction and the part is dynamicallycolored accordingly.

Flip the split direction.Show axis

Show or Hide the split axis (default on).

Show parting line

Show or Hide the parting line (default off).

Min draft angle:

Faces with draft angles less than this value areconsidered No Draft faces.


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Legend

Cavity

Faces in the cavity direction i.e. angles between the positive splitting directionand the face normal are less than (90 - defined draft angle).

Core

Faces in the core direction i.e. angles between the negative splitting directionand the face normal are less than (90 - defined draft angle).

Both directions

Name for the part containing the faces, which are in both the core and thecavity directions

No draft

Faces, which have at least one normal whose angle between the splittingdirection and the face normal is greater than (90 - defined draft angle).

No draft cavity

Faces of type no draft that are adjacent to at least one Cavity faces or otherNo draft faces only.

No draft core

Faces of type no draft that are adjacent to at least one Core faces or otherNo draft faces only.

Click on this icon to hide or show the respective surface part.

Click on this icon to open the color dialogue, which enables you to changethe color of the respective surface part.

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Move to main group

When checked the No draft cavity and Nodraft core faces will be placed in the Cavityand Core parts respectively (default). Thepreview of the color map will be updated.

After clicking the SplitWorks property page under the ( ) tab will becreated containing the folders as mentioned above as well as a folder calledParting Line(s).

These groups of faces are pointers to the solid and are NOT duplicates of thesolid faces.

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2.2 SplitWorks Property PageThe SplitWorks property page is added to the tabs at the top of the propertypage.

Cavity/Core/Both Direction/No Draft

These are the different groups of faces accordingto the split direction.

Each of the folders contains the relevant faces.

Parting Line(s)

This folder is sub-divided into Open PartingLine(s) and Closed Parting Line(s).

The RHM pop up button in this area is context

sensitive. Following are the different menus,which are displayed according to the specificcontext:

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Top menu

Select the top of the tree and click on the Right Hand Mouse button.

Automatic Rebuild

This parameter controls whether to rebuild the tree after modifications to thesolid part (default=marked).

Faces moved through the Move to menu will NOT be reclassified, and theno draft faces will not be reclassified according to the Move to maincore/cavity. This reclassification can be performed through a menu on the NoDraft folder.

Rebuild All

Force a rebuild when SplitWorks doesnt recognize a face change i.e. aftersuppressing or unsuppressing features.

Create New Group

Create a new face folder.

Import Surface

Read in surface information for an external file source and categorize it ascore/cavity or other to use in SplitWorks menus.

Hide/Show All Groups Faces

This is a toggle to hide/show ALL the faces.

Note: To get the best results when using the Hide menu use the No Edgesoption for shading (since we dont hide the wire frame).

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Face Folder

Select any face group and click on the Right Hand Mouse button.

Move to The first part of the pop-up allows you to moveALLthe faces of the group (i.e. Cavity) to any of theother groups in the SplitWorks property page.

The Both Direction group has an option CreateSilhouette to allow you to split these faces.

The No Draft group has an option Move To MainGroup to allow reclassification ofNo draftcore/cavity faces.

Create Surface/Update Surface

Create a surface from the selected group of faces.If a Surface for a specific folder has already beencreated, and the solid modified in any way then thismenu toggles to Update Surface, which will modifythe knitted surface.

Note

After a surface has been created, modifications to the solid (i.e. adding offeatures etc.) will update the face folders. Such modifications have to becreated BEFORE the knitted feature in order to be taken into account by theUpdate Surface command. There are two ways to achieve this either byrolling up the FeatureManager design tree to before the knitted surface prior tothe addition, or move the additional features to before the knit after they havebeen created.

Copy to New File

This menu will open a new part and copy the faces from the folder to it.

Create Silhouette (only if both side folder)

Split all the faces in the both sides folder according to the split direction.

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Hide Group Faces

This menu hides the faces from the selected folder. Since this hides facesaccording to shading only mark the Tools > Options > Display > No Edgesparameter under the Edges disp layed in shaded mode to hide these facesproperly (since we dont hide the wire frame).

Change Color

Change the color of the faces within the selected folder.

Select All

Select all the faces in a specific folder.

Island Analysis

Detect disjointed sets of faces for this group. This is very useful to make surethat the Create Surface function doesnt fail.

A small dialogue enables you to browse through thedifferent islands displaying them with a red outline.

Selects the current island faces and allows you to use the RHM buttonmenus on them (i.e. to move to a different folder etc.).

Rename

Rename the face folder.

Remove Group

Removes empty group (displayed only if group is empty).

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Faces within the Face Folder

Select face(s) within a specific folder from the

SplitWorks property page or from the graphic screenand click on the Right Hand Mouse button while thecursor is in the SplitWorks property page area.

Move to

This pop-up allows you to move the selected face(s)of the folder (i.e. Cavity) to any of the other folders inthe SplitWorks property page.

If the face is from the Both direction group then a further option CreateSilhouette will appear to allow you to split this face.

Zoom To

Zoom to a specific face.

Move to Cavity

Move to Core

In this case you can move the selected face(s) toonly one of these two folders.

Select faces from the graphic screen and click onthe Right Hand Mouse button while the cursor is inthe graphic screen.

Note

The original color of the face icon is not modifiedwhen the face is moved from folder to folder. Thisallows you to see where the face originated from

and perform modifications to the face if necessary.

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Parting Line(s)

Select the Parting Line(s) folder and click on the Right Hand Mouse button.

Show/Hide Open Parting Line(s)Toggle to show or hide open parting lines(default is hidden).

Show/Hide Closed Parting Line

Toggle to show/hide main parting line(default is hidden).

Automatic Parting Line(s) Rebuild

This parameter controls whether to rebuild the parting line(s) aftermodifications to the faces in the groups (default=marked).

Rebuild Parting Line(s)

Rebuild all the parting line(s).

On a specific Parting Line

Composite CurveFor any parting line in eitherParting Line(s) folder,we can create a composite curve through the RHMbutton menu.

Zoom To

Zoom to a specific parting line.

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The parting line display is useful for the following:

1. Indicating the work to be done in order to complete the separationbetween the core and the cavity as well as to make sure that the shut-offs are well defined.

2. Selection of edges for the different SolidWorks or SplitWorks menus.

3. If the Create Surface/Update Surface menu fails, use the openparting lines display to check for possible non-connected faces.

Notes

1. The property page can become corrupted if parts are hidden whenrebuild is taking place. In order to fix the problem, show the solid(s),and activate the SolidWorks > Rebuild menu.

2. When a face is moved to a different folder, it retains its original color.Furthermore when the SplitWorks property page is updated(Automatic Rebui ld is active) then SplitWorks ignores faces, whichhave been moved.


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2-13SplitWorks 2009

Summary of SplitWorks property page commands

First Level:

- Automatic Rebuild switch to automatically update the categorization

- Rebuild All forces a rebuild.- Create New Group creates a new group

- Import Surface imports and categorizes external file

- Hide/Show All Groups Faces is a toggle to hide/show ALL the faces.

Group Level (Face folders):

- Move to Core/Cavitymoves all the face from one folder to another

- Create Surface/Update Surface creates a knitted surface from the folder

- Copy to New File opens a new part and copies the faces from the folderto it.

- Hide Group Faces

- Change Color

- Select All

- Island Analysis

- Create Silhouette (Both Direction folder only)

- Move to Main Group (No Draft folder only)

- Remove Group (displayed only if group is empty).

Face Level

- Move to Core/Cavitymoves selected faces to specific group (can alsodrag between folders). Can select faces from the screen, move the cursorinto the property page to access this pop up.

- Zoom To a specific face.

- Create Silhouette (in Both Direction folder only)

Group Level (Parting Lines folder)

- Show Open Parting Lines/(Hide Open Parting Lines) shows openparting lines if there are and toggles to continuously show them and viceversa.

- Show Closed Parting Lines/(Hide Closed Parting Lines) shows closedparting lines if there are and toggles to continuously show them and viceversa.

- Automatic Parting Line(s) Rebuild switch to automatically update theOPEN parting lines


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- Rebuild Parting Lines manually rebuild the OPEN parting lines.

Parting Line level- Composite Curve creates composite curves from the selected parting

line.

- Zoom To a specific parting line.

In addition we have added Move to Core and Move to Cavity to the standardSolidWorks pop up to move faces selected from the screen without movingthe cursor to the property page.


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2.3 Plug Hole(s)

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The SplitWorks >Plug Holes menu orrelevant icon opens the Plug Hole(s) dialogue

box.

Surface Body:

You must select a part from the SurfaceBodies folder or graphic screen; SplitWorkshides the Solid Bodies automatically to assistidentification of loops. If only one knitted partexists then SplitWorks automatically selects it.

Boundary Loop(s):

The system will list all internal closed boundaryloops on the surface.

Use to leave the menu on the screen aftervalidation.

Al l Boundary Loop(s)

The system will list all the boundary loops in the surface, activatedautomatically when selecting the surface. (Use for knitted surfaces only)

Click to create the plugs for the boundary loops in the list box accordingto the following:

Plugs are created for all planar loops in the part.

Non-planar inner loops, and loops which are recognized as a result of atopological operation are deleted. Loops, which are not plugged, will be lefthighlighted. Use one of the standard SolidWorks surface functions i.e. DeleteHoles, Fill, Loft etc. to fill them.

The system will attempt to knit the result to the previously created knitsurfaces.


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Notes:

1. When using this menu, be sure to check if the faces are knitted or not,since the outer loop of a non-knitted face is a boundary loop.

2. The surface can be selected before activating the dialogue.


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2.4 LoftThe SplitWorks >Loft menu or relevant icon opens the Loft dialogue box.This dialogue is divided into 3 groups.

Edge(s)

Surface Body:

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You must select a part from the SurfaceBodies tree or graphic screen; SplitWorkshides the Solid Bodies automatically to assistidentification of loops. You can select thesurface prior to entering the menu.

Start/End:

Select 2 entities, which can be either edges orvertices, all the connecting edges (from knittedsurfaces) are highlighted. They must be freeedges.

Click to select reverse the solution (incase the wrong part of the loop has beenhighlighted).

Addi tional Edge(s)

Select additional edges to add to the lofting(they must be connected to the edges alreadyhighlighted). This is to select edges ofsurfaces, which are not knitted.

Automat ic Part ing Surface

If the Loft function automatically recognizes aparting surface (at the moment only for flatparting surfaces) then you can disregard thisby not checking this parameter.

Loft DirectionRotate the angle to the desired direction.

Click and pick an edge, the loft will bepreviewed in the 3D direction of the edge.

The loft distance will be default to the edge length.


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Click to reverse the loft direction.

Loft Distance

Define the loft distance from the edge.

Use to leave the menu on the screen after validation.

Click to create the lofted surface. The system will attempt to knit the resultto the previously created knit surfaces.

Notes:

1. If the Parting Line is a planar line, then a rectangular planar partingsurface is displayed in this case the Loft Direction then controls theorientation of the rectangle, and the Loft Distance controls the size. (Thiswill happen either when the loft menu is accessed or after the first edge ischosen)

2. The loft is created by projecting a composite curve onto a plane defined bya direction taken from the center of the original part normal to the 2 endvertices of the edges modulo 45.

3. You can select a contiguous set of edges (from knitted surfaces) byclicking on the first edge or vertex and the last edge or vertex. You can

also select edges individually. The system checks to make sure that all theedges are contiguous and free (i.e. on the surface boundary). A preview ofthe lofted surface will be displayed.

4. A feasibility check is made to avoid twisted loft surfaces, and when thesurface is not feasible (according to a quick but not thorough test) the Loftdirection is colored red.

5. This function uses a special redundancy test, which checks the success ofthe SolidWorks API functions involved and if there is a failure, it then offersthe user an iterating algorithm the lofting of the edges one by one. Onconfirmation the result will be a series of lofted surfaces instead of one,

automatically knitted.

6. A composite curve is created and projected to a plane offset at therequired distance and activates the SolidWorks loft function betweenthem. The result in the Feature Manager Design tree is the creation of theabove-mentioned elements, under a LoftSurface folder. In order to delete

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the loft surface, you should delete the 2 planes as well as all the relevantgeometry from the tree (check the Also delete absorbed features on thedelete menu to delete all the created geometry). You can also use theSplitWorks Delete menu on the RHM button to completely delete a

SplitWorks loft in one action.

7. YOU SHOULD NOT EDIT THE COMPOSITE CURVE; otherwise you willget surprising results.

8. The surface can be selected before activating the dialogue.


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2.5 Create Solid InsertThe SplitWorks > Create Solid Insert menu orrelevant icon assists you in creating an insert

(core/cavity/side core etc. from a knitted surface evenwhen the surface has not been created throughSplitWorks). An assembly of the same name as thepart is opened or created. If the assembly alreadyexists in the current folder then SplitWorks willenquire whether to create a new assembly or openthe current one.

The dialogue is broken up into three groups:

Parts

Surface:You must select a part from the Surface Bodiesunder the Part tree only. The system automaticallycalculates and displays an optimal insert blank basedon the internal Box blank.

Local coord system:

Select a coordinate system (must be in the Surfacepart) that defines extrude direction (Z+) and center forthe solid insert. It defaults to the Split directioncoordinate system.

Plastic part:

Automatically selects the plastic part. This will ensurethat the complementary insert (i.e. the insert createdby subtracting the part and the initial insert from theinsert blank) is created. The Parts group will then beexpanded to include the Comp. (Complementary)insert name parameter.

Blank:

Select the insert blank. The choices are:

Symmetric box blank (default) causes the blanks to

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be always centered on the origin in the split plane.

Asymmetric box blank enables you to adjust the width and length of theinserts in the +x(y) and x(y) directions separately.

Cylindrical blank creates cylindrical blanks.User blank... that opens an Insert Blank LibraryPalette where user createdblank folders may be defined and user blanks selected refer to section 2.8 tosee how to create a user blank.

Insert name:

Key-in the name for the resulting insert,defaults to CoreInsert or CavityInsertdepending on the parting surface.Comp. insert name:Key-in the name for the complementary insert,defaults to CavityInsert or CoreInsertaccordingly.

When the original surface is not created fromthe SplitWorks property page

In this case (i.e. if you have used the IGESin/out to knit the parting surface), then a

different dialogue box appears allowing you toreverse the core/cavity direction. The solid partmust still exist under the Solid Bodies folder inorder for this to work. The general split directionis calculated according to the z-coordinate (usethe Local coordinate system parameter tomodify the split direction it if necessary).

The Flip Split Direction:

This icon allows you to change the core andcavity directions and the Insert names

respectively.

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Position

X/YAdjust the blank on the XY plane of the Localcoordinate system relative to the origin.

AngleAdjust the angle according to the Z-axis of the Localcoordinate system.

Parameters

Click on this icon to open the parameter scheme.

The insert blank parameter scheme is a bit map filewith the same name as the insert blank.

The parameters of the blank are read in (if they arelisted in the blank initial file) according to their givennames.

Stack height (Read Only)

Displays the stack height.

Equal values for inserts

Mark this parameter so that the A, B and Cmfparameters of the core and cavity stay equal wheneither one is modified.

The following is used to modify the blank sizes.Main Parameters

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The parameters refer to the specific insert and aremodified separately. TheA, B, Cmfand R parameterswill remain equal for both inserts in the Symmetriccase.

The Thickness parameter defines the core/cavityinsert height. The initial height is defined so that thereis a 25mm (1 inch) margin from the bottom/top of thecore/cavity to the respective inserts.

Notice the data used in this section is soft coded (i.e.the bit map file, initial file and SolidWorks standard partdata), so that a user blank will behave exactly the sameas a standard library part.


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Insert Blank Library Palette

Select a blank from the Insert Blank(s) palette by double clicking on a specificpart, or by selection and clicking on OK.

Press the arrow key to hide or show the different palettes. Pressing the Folderbrowserbutton allows you to define user insert blank libraries.

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Define a user insert blank library

Click on the con to add folders to the user insert blank librarypalette.

Choose a folder with user insert blank as defined in the previous section, andclick OK to add it to the user insert blank library.

The new folder will now appear in the right hand window of the Solid InsertLibrary dialogue.

Refer to Creating User Insert Blank (section 2.8) and use a similar method tocreate your own user insert blanks.

.

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2.6 CleanThe SplitWorks >Clean menu or relevant icon allows you to clear theSplitWorks data from the part including the SplitWorks Feature Tree and color

coding. The part will revert to the default color.

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2.7 Chain EdgesThis function is accessible through the Right Mouse Button. Select two freeedges (i.e. edges on the border of a knitted surface), using the CNTRL key to

select the second edge, and click on RMB.The following item will appear.

Click on the Chain Edges button and the system will highlight a path betweenthe two edges.

This dialogue will pop up allowing you to reverse the initialchoice.

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2.8 SplitWorks DeleteThis function is accessible through the Right Mouse Button and is useful whendeleting the loft folders created by SplitWorks loft function. It should be used

with care since it deletes all the information within the folder including theunderlying 3D sketches and Composite curves etc.

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2.9 Planar SurfaceThis function is accessible through the Right Mouse Button and is useful whenyou have planar surfaces defined by a set of open edges. This function closes

the loop, creates a planar surface and knits it to the surface connected to theedges.

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2.10 Create a User Insert Blank LibrarySplitWorks insert blank - is a SolidWorks part.

Insert Blank Library is a folder containing SplitWorks insert blanks.

Here are the steps to create a user insert blanks library. Open a new folder any where on your machine for example MyBlanksLib.

Open a new SolidWorks part and Save As Blank1.SLDPRT in to theabove folder.

Open a new sketch on the front plane.

Draw a rectangle around the part origin.

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Dimension the rectangle as shown in the picture below. (Check the Showdimension names parameter in SolidWorks > Tools > Options under theGeneral tab). Name the parameters as shown below. Set Parameter A to120 and Parameter B to 220.

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Select SolidWorks > Tools > Equations and add the following twoequations: "A2@Sketch1"="A@Sketch1"/2

"B2@Sketch1"="B@Sketch1"/2


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Select Base Extrude Extrude the sketch in Z minus direction of the partcoordinate system.

Set the D1 parameter (extrude length) to 70mm.

Set the D2 parameter (extrude length at the opposite direction) to 0.01mm.

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Double click the newly created Base Extrude feature and rename the D1parameter to Depth.

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Open a new drawing file. Add to the drawing the two views shown in thepicture below.

Dimension the parameters that are to appear in the parameter box of theCreate Solid Insert dialogue.A, B and Depth.

Use the Dimension Properties > Modify Text to show only the names ofthe parameters without their values.

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[Insert Parameters] Under this section we add the parameters which will bedisplayed to the user and can be adjusted. The names of the parameters mustcoincide with the names given in the blank part.

[Primary Pocket Parameter] The parameter in this section defines thethickness of the insert.

[Secondary Pocket Parameter] This parameter must exist in order for theinsert block to be cut and is a parameter in the opposite direction to thePrimary Pocket Parameter. It is hidden and only used for calculations.

SelectUser Blank in Create Solid Insert and browse to the new blanklibrary folder and select the new blank.

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Select the icon of the parameter scheme to see that you get the right one.Notice that only the parameters:A, B and Depth are modifiable in theparameter box.

Recap

Three files are required to create a user part holder:

A solid part.

An INI file with the relevant dimensions parameters.

A BMP file of the views of the drawing of the part showing the relevantdimensions (optional).

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33 Tutorial 1

The files here can be found in the Car Handle folder under theSplitWorks\Example Files directory.


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3.1 Core and Cavity CreationIn this section we demonstrate a quick method to create the core and cavityinserts.

Select SolidWorks and open the file: HandleHousing.SLDPRT save thefile into a new folder.

Select the Split Part icon.

TheAnalysis tab is opened. The top part ofthis dialogue box is used to analyze the partin order to find an optimum parting d

irection.

Mark the Show parting line check box.

ctually the y-axis, which is the defaults,

ct an edge and then a planar face

No ft core faces is changed to light blue. In

Adirection, is optimum but by picking edgeplanar faces or planes the preview isupdated and different color schemes areshown.

Seleon the side of the part and see different

schemes. Then selectPlane2 or one ofthe planar faces on the top to return tothe optimal splitting direction.

tice that the color of the No drathis case after validating the split operation the No draft core faces will be

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categorized within a separate group.

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Under the Legend tab check the Move to main group check box. Noticethat the color of the No draft core faces is changed to blue. In this caseafter validating the split operation the No draft core faces will becategorized within the Core group.

Under the Legend tab you can Hide and Show the group of faces by activating

the icon and change the coloring default by activating the icons.

The Split Both direction part of the dialogue is for instructing the system tomake a silhouette split on Both Direction Faces. We will practice this part in the

next exercises.

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Now we will initiate the splitting process, which takes a few minutes dependingon the size of the part. Here it should take less than a minute.

Click .

A new tab at the top of the right hand pane is automatically created by thesystem.

Click .

Here we see the different groups according tothe categorization of the faces. In this casethere are no No Draft faces so this groupdoesnt appear.

An extra group containing the Parting Line(s) iscreated which in general has two sub-groupsOpen Parting Line(s) and Closed PartingLine(s),

In this case there are only Closed Parting Line(s),

We use the Open Parting Line(s) group to guide us on how to modify thefaces in order to get valid parting line(s) and shut-off(s). We will see the use ofthis in a later exercise.

In this exercise the parting line(s) are well defined so there is no need tomodify the faces.

In case where the Move to main group check box is not checked the systemwould (if faces exist) create two other groups:

No Draft Cavity faces with no draft angle that the system analyzer recognizesas cavity faces.

No Draft Core faces with no draft angle that the system analyzer recognizesas core faces.

This tab also contains a set of context sensitive menus on the Right HandMouse button to manipulate the faces in order to define the correct core (orcavity).

Select HandleHousing and click on the Right Hand Mouse button.

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Here we can see theAutomatic Rebui ld parameter (default=AutomaticRebuild), which allows automatically re categorization whenever a correction is

made to the solid part. This is an important tool, which allows immediatefeedback to the mold designer while he is correcting the part.

The Create New Group menu creates a new group to which faces may bemoved. Also the Open and Closed Parting lines are automatically displayed(here there are only closed parting lines).

The Import Surface menu is to allow the user to import and categorize asurface in external file format.

Hide (Show) All Group Faces toggle is useful when manipulating the displayof the different face folders.

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Select isometric view.

As you can see we have a problem with the bosses on the top (blue color),since they have undercuts (i.e. core faces surrounded by the cavity). Anotherindicator of the problem are the closed parting lines around the bosses.

Click on the Parting Line(s) folder in the SplitWorks property page and with

the RHM button select the Hide Closed Parting Line(s) option.This is a toggle to show or hide the different types of parting lines.

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SelectBoss-Extrude10 from the Feature Manager Design tree and clickon the RHM button and Select the Edit


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Feature pop up menu.

Check the Draft outward parameter.

Click .

The bosses are modified (they now have a suitable cavity direction). And thecolors are updated to the cavity color.

Click on the Show Closed Parting Line(s) in the SplitWorks property pageunder the Parting Line(s) folder to see the closed parting lines again.

Notice that the closed parting lines around the bosses have now disappeared.

Next we create new surface parts for the side core.

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SelectHandleHousing and click on the RHM button and Select CreateNew Group. Enter the name SideCore1.

Expand the Both Directions group and move (by selecting the Move to

SideCore1 on the RHM button while pointing to one of the faces). Create anew group called SideCore2 and move (in the same manner) the other facefrom the Both Directions group to it.

Now we create a Surface Body from the Core.

Select the Core click on the RHM but

ton and Select Create Surface.

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A new surface called Core-Surface1 appears in the FeatureManager designtree. Now we are going to close the holes.

Select the Plug Hole(s) icon automatically all the inner loops are

selected.Since only one knit exists it is automatically selected. The system will also hideall the Solid Bodies when using this menu in order to help identification of theloops etc.

Click .

All the holes are plugged. The planar holes appear with plugs (which can be

used in other parts) and the non-planar holes (i.e. for the face on the top) aredeleted.

Now we create the parting surface.

Parting surfaces can be created using any/all of the standard SolidWorkssurface construction menus as well as the Loft menu from SplitWorks whichis specially designed to create parting surfaces.

In this case we will use the SolidWorks Radiate menu for part of the surface(it is not able to create a suitable parting surface on the complete part) andthen the SplitWorks specialized Loft menu.

Click the SolidWorks > Insert > Surface > Radiate menu or relevanticon and choose the options as shown below.

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Click to create.

Knit the previous 2 surfaces, Surface-Knit1 and Ruled-Radiate1 using theSolidWorks > Insert > Knit menu or relevant icon.

Next we use the SplitWorks > Loft function.

Select the Surface-Knit2 feature under the Surface Bodies(1) tree.

Select the Loft icon.

You can also select the surface graphically after opening the dialogue.

Select the 2 vertices at the ends of the edges to loft. The second vertexshould be at the beginning of the arc.

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Select the Loft Direction box and select this edge in the picture todefine the loft direction along the edge direction.

Click to keep the dialogue active. (Modal)

Click .

The surfaces are automatically knitted.

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Select 2 vertices or edges in the Start/End box and the direction as theedge of the extended surface as shown below.

Click .

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Now we create the final loft.

Select 2 vertices or edges in the Start/End box.

Click .

Click to exit the loft menu.

The previous surfaces are automatically knitted.

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Now we create the solid inserts.

SelectSplitWorks > Create Solid Insert

menu or relevant icon .

SplitWorks automatically creates an assembly withthe same name as the part (HandleHousing),which includes the part and opens the Create Sol idInsert dialogue box.

Here we can see the first 2 sections of the d

Select the

ialogue.

Surface-Knit from the screen.

he Local coord system: defaults to thes the

t

lastic part: defaults to HandleHousing-1.

e

s the

ame and

The tate

TSplitWorks Coordinate System defined a

center of the bounding box when the part was firssplit.

The P

SplitWorks automatically calculates the largest sizof the specific blank chosen that covers the surface,taking the Split direction coordinate system acenter of the blank and the extrude direction. Herewe can choose Symmetric andAsymmetric boxblanks from the standard (Symmetric blankautomatically centers the blank around the x, ycoordinates, while theAsymmetric blank allowsdifferent values for +x (y) and x(y).

Key-in CoreInsert for the Insert nCavityInsert for the Comp. Insert name.

Position group allows you to move and ro(around the z-axis) the insert blank. We will leavethe default.

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lanks

ly

The Parameters group allows you to change theparameters of each of the inserts separately ortogether ifEqual values for inserts is marked.These insert blanks (i.e. material). The insert b

exist in a standard (user extendable) library on thesystem. The Stack height: parameter is read-onand keeps track of the stack height. The initialheight is defined so that there is a 25 mm (1 inch)margin from the bottom/top of the core/cavity to therespective inserts.

AdjustA and B to 220 and 135 respectively andsee that the Cavity insert also is automatically

adjusted. Click on the See parameter scheme icon (to

see the meaning of the parameters).

Click .

The Surface-Knit is automatically hidden and the SolidCut-Extrude isdisplayed.

Explode the assembly.


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Notice that the cavity includes the ears of the side cores. These could beused as side cores since they appear in the cavity insert as separate bodies.We could just add an extrusion to each one and then split the CavityInsert intoa three parts assembly including the side cores.

In this tutorial we will create the side cores using the faces we have set asidein the SplitWorks property manager to show an alternative method which mightbe preferable in a more complicated case.

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3.2 Side CoresHere we will demonstrate the creation of a simple side core, in fact a pin. Thesame steps would be taken even if the side core consisted of complicated

geometry. It is in fact similar to the method we used in creating the core. Open HandleHousing.SLDPRT

Show only Cut-Extrude15 underSolid Bodies for convenience.

Under the SplitWorks property page select SideCore1 andclick on theRHM button and chooseCreate Surface. If the property page is notcomplete then switch on theAutomat ic Rebuild option and activate theSolidWorks > Rebuild menu.

Select the Plug Hole(s) icon identify the SideCore1 surface under theSurface Bodies tree (SideCore1-Surface1) and select the back circle as

the loop to close.

Click .The plug is created and knitted to the surface.

Select the SolidWorks Insert > Reference Geometry > Plane menu or

relevant icon .

Select the planar face and input a Distance of40 (if the left hand side coreor50 if the right hand one).

Click .

Open a sketch (on the last created plane).

Select the open loop and click the Convert Entities icon.

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Select SolidWorks Insert > Base > Extrude... menu or relevant icon andchoose the typeUp To Surface. The directionshould be towards the center of the part, if notcheck the Reverse box.

Uncheck the Merge resul t parameter. We wantthe side core as a separate solid object.

Click .

Perform the same forSideCore2.

At this stage we have three Solid Bodies in theFeature Manager tree.

Click on SolidWorks > Window and select openHandleHousing.SLDASM

Edit CoreInsert and create a cavity feature with HandleHousing.SLDPRTThe holes for the side cores appear.

Show only CavityInsert and CoreInsert.

Automatically the Core is updated to include the holes created by the sidecores. This is an important characteristic of SplitWorks system, whichmaintains coherency of the mold.

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3.3 Propagation of part changes to the core cavity and sidecores.

Open in the Example Files\Car Handle folder.

Notice that the handle axis is not concentric to the housing axis. This is due tothe fact that in the parallel working process the core and cavity are alreadydesigned while a revision change comes in. Since SplitWorks maintainscoherency functionalityrevision changes will propagate to the core cavity andside cores.

Edit and Edit sketch. Changeto normal view.

Change the dimension 40.0mm to 20.00mm

Now the axis is concentric.

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Here are some more changes to the part.

Edit and change to normal view.

Add a length Dimension to the opening and change it from 10mm to 15mm.

Edit definition of . Change the radius from 10mm to 6mm .

This is the new revision of the part.

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Close and validate all SolidWorks request for saving andassembly updates.

Notice that all changes were propagated to the core cavity and side coresparts in the HandleHousing assembly.

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The fillet on the top has been decreased, the size of the bosses has beenincreased and the axes (ears) have been moved and the side cores updatedaccordingly.

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3.4 Cavity PinsIn this section we demonstrate how to make cavity pins with SplitWorks. Againthe example is a simple one, but the same steps can be used for any

geometry. This is similar to the Side Cores step. Open HandleHousing.SLDPRT

Show only the Cut-Extrude part underSolid Bodies for convenience.

SelectHandleHousing and click on the RHM button and Select CreateNew Group. Enter the name Pin1.

Create new groups with names Pin2 and Pin3.

SelectCore and click on the RHM button and chooseHide Group Faces.

In the SolidWorksOption menu under the Display tab mark No Edges in theEdges display in shaded mode section.

Select a pin from the screen, move the cursor into the SplitWorks propertypage, click on RHM button and choose Move to Pin1.

Do the same for the other 2 pins.

SelectPin1 and click on the RHM button and chooseCreate Surface.

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Select the Plug Hole(s) icon identify the Pin1 surface under theSurface Bodies tree (Surface-Knit10) and select the narrow circle as theloop to close.

Click .The plug is created and knitted to the surface.

Do the same for the other 2 pins.

Close HandleHousing.SLDPRT to return to the Assembly of the samename.

Edit HandleHousing. (It is useful to force transparency when editingassembly through the SolidWorksOptions menu.

Select the SolidWorks Insert > Reference Geometry > Plane menu or

relevant icon .

Select the planar plug face (of a pin) and input a Distance of60.

Click .

Open a sketch (on the last created plane).

Select the open loop and click the Convert Entities icon.

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Select SolidWorks Insert > Base > Extrude... menu or relevant icon andchoose the typeUp To Surface. The direction should be towards thecenter of the part, if not check the Reverse box.

Uncheck the Merge resul t parameter. We want the core pin as a separatesolid object.

Click .

Next we build a shoulder.

Select the top face ofPin1 and open a sketch.

Select circle; make it concentric to the top face of Pin1 with offset 5.

Select SolidWorks Insert > Base > Extrude... menu or relevant icon andchoose type blind, Distance 5 in a direction towards the pin tip.

Check the Merge resul t parameter

Click OK.

Do these steps forPin2 and Pin3.

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Hide HandleHousing.SLDPRT to see that the holes for the cavity pinshave automatically been created.

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HideCoreInsert and show CavityInsert only.

ShowPin1, Pin2 and Pin3 (within HandleHousing.SLDPRT).

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44 Tutorial 2

In this tutorial we will focus on how to define the parting line of both directionfaces in the analysis face. The files here can be found in the Car Handle folderunder the SplitWorks\Example Files directory.


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4.1 Parting Line on Both Direction Faces Select SolidWorks and open the file: Handle.SLDPRT and save it into a

new directory.

Select the Split Part icon.

Press the Flip Direction .

The orange faces that you see in the part window at the bottom of the partare Both direction faces. Faces that part of them should go to the cavitygroup and part of to the core group. SplitWorks can suggest at this stagethe missing parting line.

Mark the Show parting line(s) check box.

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The orange faces in the list are the faces that the system is going to split alonga silhouette parting line. As a default all Both directionfaces are included inthe list. In this case we do not want the axis faces to be included in the list.

Check the Move to main group box under the Legend tab. There aren'tany No Draft Cavity/No Draft Core faces anyway.

Select the inner face of the axis. The face is deleted from the silhouette listand its color set to Red indicating that the parting line will not split this face.

Follow same steps to delete both chamfers of the axis. Make sure that theircolor is changed to Red.

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Select the Create silhouette icon.

The faces in the list are split along the parting line. Notice that the maincore surfaces created by the parting line surfaces were assigned to theCore surfaces group and were colored blue. Some of the faces are stillassigned to the both direction faces, and the parting line is purple denotingthat it is not closed. This is due to a tolerance problem and can be solved

by adjusting the Silhouette angle parameter.

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Set the Silhouette angle parameter to 3. (We could adjust the angleincrementally until the faces move to their


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respective sides (i.e. to the core or cavity) but this might take some time instead we will give an angle to be sure that the faces are resolved andthen find the minimum angle)

The parting line for the hole becomes yellow showing that it is closed.

Click on and the angle adjusts to .14 (the minimum angle for which thefaces will be properly divided)

We use the Silhouette angle as a parameter to help tune the analysis in orderto get a clearer result. In general the size of the Silhouette angle is not animportant factor.

Unmark the Show parting line(s) check box.

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Hide CavityandBoth Directionunder the Legend tab to see only thecore faces.

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Click to create the SplitWorks property page.

Select the Core click RHM button and choose Create Surface.

Click on Hide Closed Parting Line(s) in the SplitWorks property page.

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4.2 Parting Surface Hide Solid Body.

Activate the Plug Hole(s) icon.

Click .

The hole in the middle is left highlighted (selected). This makes it convenient touse the SolidWorks > Filled Surface menu.

SelectInsert > Surface > Fill for the standard SolidWorks menu.

Mark the Merge result option.

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Click .

We will now create the parting surface.

Activate SolidWorks Radiate Surface icon.

Select the round edge as shown in the picture below.

Select the round face.

Set the Radiate distance to 100mm and clickOK.

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Knit the surfaces together.

Select theSurface-Knit from the Surface Bodies folder.

Activate the Loft icon.

Activate the Keep Visible icon.

Select start and end edges as shown in the picture below.

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Activate the Angle from picked edge icon and select the edge shownin the picture below.

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Notice that the length of the surface fits the previous radiate surface (since wetake the distance from the length of the edge chosen).

Click .

SplitWorks might display a message indicating that it was not possible tocreate the loft as one surface and that SplitWorks will iterate through theedges.

ClickOK.

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We will now follow similar steps to get the surfaces on the other side.

Select start and end vertices/edges as shown in the picture below.

Activate the Angle from picked edge icon and select the edge shownin the picture below.

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Click to get the following result.


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SplitWorks might display a message indicating that it was not possible tocreate the loft as one surface and that SplitWorks will iterate through theedges.

Select start and end edges as shown in the picture below.

Click

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Select the remaining 2 edges.

Click to get the following result.

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55 Tutorial 3

This tutorial demonstrates a real life part, which is given in IGES format andwill demonstrate the different steps taken in SplitWorks to create the inserts forthis part. The file here can be found in theAbdeck folder under theSplitWorks\Example Files directory.


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5.1 Organizing DataIn this part of the tutorial we will cover the following steps:

- Read in part data.

- Enlarge part for shrinkage factor.- Set the coordinate system of the part.

5.1.1 Read in part data

Open the IGS fileAbdeck.igs.

After SolidWorks reads the IGES file a message is displayed offering to run thediagnostic tool.

Click Yes.

Zoom to the marked area.

There is a small tear in the solid, which should be first fixed.

Zoom up closer and select the face inside the small tear and use the RHM

button to delete it.

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A Gap will appear - click on theAt tempt to Heal Al l icon on the bottom of thediagnostic dialogue to close it.

Click to exit the dialogue.

SaveAbdeck.SLDPRT.

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5-4SplitWorks 2009

5.2 Modify Part for ManufactureIn this section we will see the tools available to analyze, modify and create thecavity surface used to form the inserts.

- Core and cavity face analysis, creation of silhouettes according to userdefined directions and draft angles.

- Dynamic parting line and face color display to assist modification of thecavity faces for mold design.

- Preparing relevant cavity faces and creation of cavity surface.


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5.2.1 Silhouette parting line

Select the face as shown below to define the split direction.

Activate SplitWorks > Split Part . The split direction is according toselected plane.

Mark the Move to main group check box under the Legend tab.

Activate Create Silhouette .All both direction faces colored in orangewill be divided according to the main split direction.

Notice how the parting line (i.e. the divide between the core and cavity) hasimproved.

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However, you can see that the part still has to be modified in order to create a

complete parting line.

We will ignore the parts that obviously require side cores and deal with themafter creating the main core and cavity inserts.

Click .

Note:

We have made a decision to create the cavity first and the core as a result. Wehave also decided to create the side cores afterwards using SolidWorks tools

so we will ignore the both side faces to begin with.

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5.2.2 Complete the Part ing line

In order to complete the parting line we need to split more (flat) faces

connecting the silhouette parting line and the parts natural parting linedetected by SplitWorks (edges connecting blue, core, and green, cavityfaces.). There is no unique solution to complete the parting line. This is a stagewere designer experience and preferences take a role. Working on thebackground of the colored faces makes it easier to create the missing theparting lines.

Click on the SplitWorks tab to see the different groups created.

Select onAbdeck click on RHM button and see thatAutomat ic Rebuild ischecked; this automatically updates the SplitWorks property page after partmodification.

We are going to make changes to the part in order to close the parting line.

Zoom to the area shown in the picture above. The selected edge in thepicture is the silhouette parting line created in the steps before.

We are going to correct the parting line in this area.

Select the face shown in the picture, and open a new sketch.

Select the silhouette parting line shown in the picture above. Use ConvertEntities to copy the edge to the sketch.

Extend the new line as shown in the picture below.

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Activate SolidWorks > Curve > Split Line and select the 4 faces shownin the following picture.

Click .

Now we are going to use the SolidWorks draft function to correct the splitfaces. SplitWorks automatically rebuilds the SplitWorks property page.

Select the SolidWorks > Insert > Features > Draft or click andchoose the Parting Line option as the Type of draft.

Select the face used for the split direction forDirection of Pull. Make sureit points to the cavity direction.

Select the parting lines from the previously split faces as shown below.

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Open a sketch on the face and draw a vertical line from the vertex as shownin the picture below, and select SolidWorks > Split Line > Projection tocreate a split line.

Zoom to the following area.

As you can see there are two areas (as shown within the circles that have thesame problem; a small part of a core face has to be moved to the cavity. Wewill split the faces and correct the draft angle.

Open a sketch on the face and draw a vertical line from the point on theseparation line.

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Split the face using the SolidWorks > Split L ine menu (within the sketch).

Click .

Select the SolidWorks > Insert > Features > Draft or click andchoose the Parting Line option as the Type of draft.

Select the face used for the split direction forDirection of Pull. (Makesure it points to the cavity direction.

Select the parting lines from the previously split face as shown below.

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Draft the front face (with Neutral Plane option) in the cavity direction.

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Recreate the fillets on the corners where the previous fillet was using Insert >Surface > Fillet/Round and set the radius to 3.

In order to finish the parting line (to make sure that the part is correctlyseparated, move the no draft faces in the screen below to the core. This is animportant part of the process in order to check that the parting line is welldefined.

The result.

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Now we want to check all the closed parting lines.

Select the Hide Open Parting L ine(s) from RHM button on the PartingLine(s) folder from the SplitWorks property page.

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In this area there is no parting line for the shut-off.

In the second circle there seems to be a closed parting line (i.e. an undercut)

This is a problem with the solid definition but does not interfere with the workitself and will disappear when creating the cavity surface.

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Zoom to the second circle and see that there is a face in the wrong direction.

Select the SolidWorks > Insert > Features > Draft or click andchoose the Neutral Plane option as the Type of draft.

Select the face used for the split direction forDirection of Pull. (Makesure it points to the cavity direction.

Select the undercut face to change the draft angle. The face is moved into

the Cavity folder.

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Now we deal with the cut-of in the middle.

Zoom to the square shut-off and show one side.

Create a diagonal split line as shown in the screens below.

Follow similar steps (open sketch on planar face and add diagonal line) to splitboth side faces of the square hole as shown in the picture below.

In order to complete the parting line, move the faces above and below to theCavity and the Core groups until you finally get the following closed parting

line.

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Browse to the Next Island and do the same until all the Islands havedisappeared. Then Close the Island Analysis dialogue.

Select Cavity, click RHM button and choose Create Surface.

A Surface Body has now been created (if not go back and check that thecavity folder does not contain disjointed sets i.e. do the Island Analysis

again). Select the Hide Closed Parting Line(s) from RHM button on the Parting

Line(s) folder from the SplitWorks property page.

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Select the vertex as end point.

Change the loft direction to 180.

Change the loft distance to 45.

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Click

During the loft process we get the following message:

Click OK.

The parting surface is created and knitted with SplitWorks iterating through theSolidWorks loft function to finish it.

Activate the Loft function .

Select the two edges as start and end entities for the loft chain.

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Again ignore the pre-loft warning.

Set the Loft direction to 270 and Loft Distance to 45.

Click the docking pin .

Click

Click OK on the SplitWorks warning message.

Again there are no gaps in the surface, and SplitWorks automatically knits thesurfaces together. (If there are then just close them by using the SplitWorksPlanar Surface menu on the RHM button as before)

Now we loft the third side.

Select both end vertices as shown below.

Ignore the pre-loft warning.

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Set the Loft Direction to 360.

Set the Loft Distance to 45.

Click

Click OK on the SplitWorks warning message.

Now we are left with gaps in the surface.

Click to exit the Loft menu.

Here we use the SplitWorks Planar Surface RHM button menu to fill in themissing gaps.

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5.3.1 Solid Cavit y and Core

In order to create the core and cavity we will use the Create Solid Insert

menu.

Activate SplitWorks > Create Solid Insert or relevant icon .

SplitWorks automatically opens or creates an assembly by the same name asthe part includes the part and opens a dialogue.

Select the surface from the Surface-Bodies folder in theAbdeck.SLDPRT. The Plastic part is automatically chosen.

Except the default blank, choose the names CavityInsert and CoreInsert

for the Insert name and Complementary insert respectively. Key-in 50 forThickness of both CavityInsert and CoreInsert.

Click .

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5.4 Side CoresIn this exercise we did not use SplitWorks functionality to move side core facesto new parts as a method of creating the solid side cores. In this exercise we

will extract the side cores directly from the solid core.5.4.1 Side Core 1

Open a new part and name it .

Insert CoreInsert (the solid core) as a part to the new created part.

Open sketch on the face shown in the following picture.

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Draw the following sketch while you are wire frame mode.

Cut Extrude Through all. Make sure to flip the side to cut.

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Save.

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If the last Cut-Extrude doesnt work then move the plane to .1 mm from theface.

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5.4.3 Extract side cores from the core.

Open a new part and name it CoreMinusSideCores.

Insert CoreInsert, as a base part. Open a new assembly and name it CoreInsertFin.

Drag and drop to origin the 3 parts: CoreMinusSideCores,SideCoreSLD1 and SideCoreSLD2.

Activate the SolidWorks Cavity function to subtract SideCoreSLD1and SideCoreSLD2 from CoreMinusSideCores. Make sure that theshrinkage factor is set to 0.0000.

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66 Tutorial 4

In this tutorial we are going to show some of the new UNIQUE functionality ofSplitWorks, which enables corrections to the part (whatever they may be) to bedown streamed to the final inserts through our unique Update Surfacefunctionality.

In the first tutorial we demonstrated modifications, which were made on thepart WITHOUT adding or deleting features. Here we are going to show thegeneral modification of parts including addition/deletion of features and evenmodification of an IGES file.


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automatically created.

Click .

Click on the SplitWorks > Create Solid Insert menu and select thesurface from the screen.

Click .

Explode the assembly.

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6.1.2 Correcting the original part

OpenCover.SLDPRT.

Edit the featureCut-Extrude17.SLDPRT. The change we are going tomake is to create a hole instead of the pocket, which will belong to thecore.

Change the End Condition to Up To Next.

Mark the Draft outward check box.

Click .

This is a major change, which will cause difficulty for most splitting procedures.

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Now we must update Cavity-Surface1.

Roll down to afterCavity-Surface1.

Select the Cavity folder from the SplitWorks property page, click on theRHM button and press Update Surface.

There is a new hole, and a shut-off for it has to be made. The shut-off shouldbe made before Surface-Knit2 so that we can add it to make sure that the restof the parts are coherent.

Hide the solid (Split L ine2) under the Solid Bodies folder.

Select Cavity-Surface1 under the Surfaces Bodies folder and click onSplitWorks > Plug Hole(s)menu or relevant icon.

Clearthe Boundary Loop(s) selection box.

Select an edge from the new hole.

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Click .

Roll down to below Surface-Knit2, edit and add the last created surface(Surface-Plane11).

Click .

Roll down to the end and show Surface-Knit3 under the Surface Bodiesfolder.

The parting surface has now been completely updated.

HideSurface-Knit3 underSurface Bodies and show Split Line2 underSolid Bodies.

Open Cover.SLDASM. The assembly updates to include all thecorrections!

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Important Note:

The process of modification has two separate steps:

First Step (modification of the part)In order for theAutomatic Rebuild (color classification) and Update Surface(insert surface update) functionality to work correctly the modifications of thepart must be made prior to the creation of the surface (Create Surface) menu.

This can be achieved either by rolling back the feature tree to before the insertsurface or if the original part was added as a base part. (If you forgot to do thisyou can always move the modifications back to before the insert surface wascreated).

In the previous part the actual modification of the part was created before theinsert surface however, we had to add a new split feature, which must also beadded before the insert surface.

Second Step (modification of the parting surfaces)

As a result of modifications of the part new shut-offs or different parting lineshave to be accounted for. This must be performed on the feature tree withinthe context of the relevant parts i.e. adding the shut-off must be done beforethe knitting of all the holes and added to that knit in order to preserve thecoherency.

In the previous part we had to create and add a new shut-off to the knitsurface, which contained all the other shut-offs.


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6.2 Changes in an IGES fileThe parts for this section exist in the IGES folder underSplitWorks\ExampleFiles.

6.2.1 Creating the inserts Open the file dek.iges. (No need to perform diagnostics)

Select the top face and click on the SplitWorks > Split menu orrelevant icon (since the part has not been saved you will be asked to saveit).

Mark the Move to main group parameter under the Legend tab.

Click .

We are going to create the core surface. We can see both the main partinglines and some open parting lines where we have holes.

Zoom to one of the pairs of open paring lines as shown below.

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Modify the draft angle of the no draft face so that they become part of thecore, using the Insert > Features > Draft menu or relevant icon,choosing the bottom face as the direction and the 4 faces (one for each ofthe snaps) to draft.

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Click .

Notice that the core and the open parting lines are updated. The other no draftfaces obviously belong to the cavity part and we will ignore them, althoughtheir draft angle might have to be corrected.

Select the Core folder from the SplitWorks property page, click on theRHM button and press Create Surface.

Hide the Parting lines.

Click on the SplitWorks > Plug Hole(s) menu or relevant icon.

Obviously Plug Hole(s) cannot fill these holes and we will use standardSolidWorks tools to create the shut-offs.( SolidWorks Parting Surface menu

doesn't close them properly either)

Here we will create the cut-off on one hole and use the Copy Surfacecommand from SolidWorks to translate and rotate it to the other holes.

Create 2 curves using the Curve Through Reference Points menu asshown in the screen below.

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Knit the last few surfaces (afterCore-Surface)

Select the Insert > Surface > Move/Copy menu to move the previousknit surface to the second hole on the same side using the translate (76 or-76 mm in the Z direction) and mark copy, the use it again to rotate the 2surfaces around the center point by 180 degrees (y direction) again withthe copy parameter marked.

Knit all the surfaces together.

SelectSurface-Knit from the Surface Bodies folder and click on theSplitWorks > Loft menu to create the loft surface. SplitWorksrecognizes that it is a planar surface. Make the distance 25.

Select the SplitWorks > Create Solid Insert (or relevant icon) andcreate the core and cavity inserts, modifying Thickness (material margin)for both the core and the cavity to 15 (i.e. Stack height of 30).

Click .

Explode the assembly with the SolidWorks Explode function.

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Save the result.

6.2.2 Reading in a modif ied IGES fi le

Now for the interesting part we will read in an IGES file which is a correction ofthe previous file.

Open dek.SLDPRT.

SelectImported1 and with RHM button click on Edit Definit ion.

Choose dekModified.IGS and clickOpen.

Notice that the new file is created and the SplitWorks property page updatedwith the correct face coloring. At this stage corrections could be made to the

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core if the part needed them, however, in our simple example no correctionsare necessary.

Select dek.SLDPRT under the SplitWorks tab and click on the RHM button.Choose the Rebuild All Select the Core folder from the SplitWorks propertypage, click on the RHM button. Instead ofCreate Surface the menuUpdate Surface appears since the Core-Surface already exists.

Activate Update Surface.

OpenDek.SLDASM from the Window menu.

The inserts have been automatically corrected.

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