xelerate mold project

Xelerate Mold

CimatronE 8.5 Tutorial

CimatronE 8.5 Xelerate Project i

Table of Contents

Xelerate Mold Project ......................................................................................................... 1 Start a new project ........................................................................................................... 1 Split Directions ................................................................................................................ 4 Assembly mirror & Copy .............................................................................................. 15

Assembly mirror......................................................................................................... 15 Add slider....................................................................................................................... 20 Load Mold Base............................................................................................................. 25 Working on the Fixed Side ............................................................................................ 27 Parting Surface Part ....................................................................................................... 38 Export Parting Surface Part ........................................................................................... 52 Core insert...................................................................................................................... 59

ii Xelerate Project CimatronE 8.5

CimatronE 8.5 Xelerate Project 1

Xelerate Mold Project

Start a new project

Start a new project

Start a new Mold project.

Name the main assembly: Xelerate

Check the Create a new folder box to create a folder, for placing the main assembly under.

To load a predefined layout part, click the open icon. Select the part: Layout-4-Cav-mm.elt. Click the Select option.

Select OK.

2 Xelerate Project CimatronE 8.5

Load Work Click the Load Work Parts icon.

Select the part called ModelXL, select OK.


Place the work files onto the two UCS’S on the upper side. Select the Edit Work UCS button.

Select 'Yes' to confirm the load operation.

Select the lower middle point as the new Work UCS.

Select OK twice.


Edit the layout sketch. Change the distances between the squares and the layout UCS to 28.

Split Directions

New Direction Step1 From the Parting option select New Direction.


Select one of the model faces. Exit

Press the Auto Selection button.

The system analyzes the faces and the relevant faces are selected according to the defined direction. Faces with a Cooling or Ejector Pocket attribute are ignored by Auto Selection. This option is grayed out if the option Both Directions is selected.


Select the optional stage: Direction analysis.

This optional step opens the Direction Analysis function within the feature guide and enables you to display the Draft Angle Analysis color dialog and show the local draft angle when moving the cursor over the faces selected for assignment, before approving the operation.

We will later see how to update the exported split direction, therefore un attach the face indicated by the arrow in the picture below (although it does belong to this split direction)

Select Apply.


New Direction Step2

Select one of the lower faces. Press the New direction button.

Flip the arrow direction and select OK.


We will now edit the split direction and add the missing faces

Right click the Split 02 direction from the parting tree. Select the option: Edit Direction.

Note that the Ignore Assigned Faces is on. Ignore Assigned Faces: Faces that are already assigned to a split direction set will not be selected for inclusion in a different set.

Select the other faces 'By Box'. Do not select the 'Slider' faces.


Attach faces that belong to the lower split direction which were not attached automatically. See the face indicated below:

Select OK. (You may use the analysis before approving the operation)


Ensure the indicated face is still not attached.

New Direction Step3

Right Click the front face of one of the work parts. Select the option: Split.


Select the face indicated by the arrow in the picture below as the splitting face. Select Apply.

Create another split with the other face. Select Ok.


New Direction Step4

Create a new Split Direction. Select the face indicated by the arrow in the picture below:

Click the direction arrow, select 'Along Y'.


Press the Auto Selection button (Ignore Assign Faces).

New Direction Step5 Unselect the two faces shown below:

Select OK.


Attach the previously unselected two faces to the lower split direction.

Drag the slider to view the result.


Assembly mirror & Copy

Assembly mirror

Assembly mirror Step1 Activate the Parting assembly. Create a Plane - Main Planes - ZX.

Click the Filter UCS to select the parting UCS.


Select OK.

From the Assembly menu, select the option: Mirror part.

Select one of the work parts.


Assembly mirror Step2 Select the previously created plane.


Select OK.

Note that the Split direction attributes were copied together with the part.


Assembly copy

From the Assembly menu, select the option: Assembly Copy.

Select the mirror part, the origin; layout ucs, and the target; second layout ucs.

Select OK.


Add slider

Add Slider Step1 Activate the main assembly. Add a new Sub Assembly, name it "Sliders". Place it on Assembly UCS.

Load a Slider Unit. Select the Angle Pin Slider \ Slider core Mechanism Assembly Z 180.


Place the assemblies on the two layout UCS:

We will first copy the layout UCS to the active assembly. From the Datum menu, select the option: UCS\Copy . Copy the two UCS as indicated by the arrow in the picture below. (Each at a time). Select the XYZ Delta option; DeltaX = 0, DeltaY=0, DeltaZ=0.

Place the Slider assembly on the two copied UCS as indicated by the arrows in the picture below:


Rotate by Z Axis = -90.

Add Slider Step2

Press the Edit Parameters button. Edit the Slide Z 180 part.


Select the row: Z180 32XL1X63; b1=63, l1=100. Select OK.


Change the Delta values as follows: Delta Y = 50.


Load Mold Base

Load Mold Base Before loading the Mold, you may change the layout dimensions according to the Slider size. Update the

layout dimensions as shown in the picture below:

Load new Mold Base. 9 plates B. 446X546; Mold Orientation = 0. Select Next.


Change the plates heights as follows: P2 = 66, P3=36, R1=96. Select Finish.


Working on the Fixed Side

Export To Part At this early stage, you may already start working on the active parts.

Display only K20 in the fixed side and the parting assembly.

Select the Export to Part icon from the Guide.

Notice the three options to export a part.

Pick Target Part

This option enables you to export parting faces to an existing part. One or more split directions are created in the target part. Each exported parting face is placed in a newly created split direction, identical to the original split direction of the parting face, in terms of relevant attributes.

Pick Target Split Direction

This option enables you to pick the target split direction in the target part. All parting faces are exported to the target part and receive all relevant attributes of the target split direction.

Pick an active face/split direction in the target part, using the display or the tree, and exit.


Pick Target Sub-Assembly (Export to New Part)

This option enables you to create a new part under a picked sub-assembly. New split directions with the attributes of the input parting faces are created in the new part and parting faces are assigned to it accordingly.

Pick a target sub-assembly to place the new part, using the display or the tree, and exit.

When this option is selected, the Target Part parameter is now displayed as Target Assembly (see below) and an additional parameter (New Part Name) is displayed showing the default name of the new part.

Accept the default option. Select K20 as the Target Part. Exit


Note that K20 was identified as the target part.

The display of the plate turns into Wire Frame mode, to enable an easy selection.

Select the four groups of active faces (blue faces). Select OK.

Hide the parting assembly.


The split directions with their attributes are now appears in the parting tree under K20.

Modifications and Updates Basically there are three main types of modifications that may occur during the mold project:

1. Geometrical changes

2. Transformation changes

3. Adding/Removing active faces

Apply a geometrical change by changing the scale of the Work part to 1.005


Notice the Question mark next to K20 ( Fixed Side). This indicates that the changes affects K20 and therefore it should be updated.

Before updating the Fixed side, update the mirror work part by associating it and later disassociate it.

Associate the Import feature.

Disassociate it. (To prevent cyclic dependencies)


Update the Fixed Side

Display the parting assembly and K20. Notice the gap between the active faces of K20 and the work file, due to the scaled work part.

Activate the K20. Notice the exclamation mark next to k20 which notify of the changes. Right click the Export feature, select Update & Disassociate.


Note that the active faces in K20 were updated.

Edit Layout We will now examine the second type of changes, by editing the layout.

Edit the layout, change the distances from 28 to 30.


Note that the exported part is not automatically updated.


Activate K20. Right click the Export feature, select Update & Disassociate.

Add face to split direction We will now apply a change to the content of the split direction by adding a face.

Add the unassigned face indicated in the picture below. Select the face using the QuickSplit option.


Move the mouse over the blue face indicated by the arrow in the picture below: Exit (Middle Mouse Button) to attach it to the upper split direction.

Repeat the same operation with the mirror part.

Exit the Quick Split tool.


Display only K20.

Activate K20in the fixed side. Right click the export feature and select: Update & Disassociate.

The face was added to the K20 plate in the fixed side.


Parting Surface Part

Main PSP We will now add the parting surface parts.

This mold will be composed of cavity plate as active part in the fixed side, and two inserts (each composed of model and a mirror model) in the movable side.

In multi cavities it is recommended to create two types of Parting surface part:

Main: the parting surface that usually hold the outer boundary of all instances. This parting surface part will be placed on the main assembly UCS of the parting assembly.

Local: the parting surface that is common to all or some of the instances. This parting will be placed on one of the instances UCS.

From the guide, select the option Parting Surface Part.

Name it Main.


Place it on Assembly UCS.

We will not create the parting surface yet, we will first add a local parting face.

Local Step1 Add another Parting Surface Part. Name it: Local.


Place it on the two UCS as indicated by the arrows in the picture below:

You may highlight split direction in the tree through the display area. Right click the face indicated below' select: Highlight Split Direction. The relevant split direction is now highlighted in the tree.


Right Click the highlighted split direction in the tree, select the option: Hide other, to hide all other split direction (only the blue faces remain)

Local Step2 We will now create an extended face in the local parting surface part. Therefore we will first unstitch the active faces.

Ensure that the local parting surface part is active.

Unstitch the faces by selecting the As Group option.


Create a composite curve.

Note that if you select the wrong instance by mistake (not the active one), you will see the preview in the wrong selection.


Create an Extended Planar & Cone face.

Using this option, the user may pick a set of stitched (and adjacent) planar/cylindrical/conic faces (or NURBs faces that can be simplified to such types) and to extend them to a reference geometry (which defined by a sketch or 2d wire).

Select adjacent planar & cone faces. Select them by box as indicated by the arrow in the picture below &

Exit


All the free edges of the selected faces selected are highlighted.

You are now requested to select a reference closed sketch. (You may also select a planar face instead).

Enter the sketcher on the XY plane. Create the following sketch. Show the layout part to ensure that the sketch exceeds the boundaries of the mold.


Local Step3

Exit the sketcher. Select OK.

The faces are extended toward an "imaginary" sweep face created by the sketch.


Note that the internal parting faces were also created.

The Upper /Lower Delta value controls the "cupping" plane/face of the upper & lower bounding box of the selected faces.

More information regarding Upper /Lower Delta value:

In our example it is obvious that the extension of the vertical face will never reach the "imaginary" sweep faces. Although it is the required result in our case, but in other cases we would sometime like to extend these faces.

Therefore we will use the Upper /Lower Delta value. The system creates (internally) a bounding box of the part using the UCS defined by the sketcher plane. The system then creates "imaginary" sweep faces that run from the lower plane (parallel to the lower box boundary with the defined delta) to the upper plane (parallel to the upper box boundary with the defined delta).The "imaginary" sweep faces defined where the extension will be stopped.


See example below with Upper /Lower Delta = 10:


Local Step4

Activate the Parting assembly. From the Assembly menu, select the option: Mirror Part. Select the Local parting surface part as indicated by the arrow in the picture below:

Select the mirror plane


Select the option:Assembly copy option. Select the Local mirror parting surface part.Exit

Select the reference UCS

Select the target UCS.


Complete the main PSP

Activate the main psp. Create a sketch on the XY Plane.

Show the movable side to ensure that the sketch exceed the plates.

Create a Composite Curve - 2D single indication as shown in the picture below:


Create a bounded face.

Export Parting Surface Part

Export Parting Surface Part Step1 Generally you do not have to attach attributes to parting surfaces prior to the export operation. However It is recommended to do so incase the mold has many components, to get a clearer idea of the relations of the parting surfaces.

Select the Export Parting Faces icon from the Guide.


Show the plate K20 in the fixed side. Select it (K20) as the Target Part. Exit

The system temporarily change the plate mode to Wire Frame to enable smooth selection of the parting faces.

We will now select the parting faces to be exported to the plate.

Select by box all the parting faces.

Note that the parting surfaces may belongs to different parts.


Since the Export operation, by default, comes with a cut operation of the target part with the stitched parting surfaces, the Open Edges display, helps you to detect problematic areas if any.

Do not exit yet, we will now see another way of picking the desired faces. We will use the option: Pick a Split direction with attached parting faces.

Cancel the Export Parting Faces operation.

We will first attach attributes to the parting faces.

From the Guide, select the option: Parting \ Parting Attributes.


Select the parting faces indicated by the arrows in the picture below:

Select the split direction of both sides. (Core & Cavity).

Select the main parting surface.


Attach it to the split direction as indicated by the arrows.

Export Parting Surface Part Step2 Select the Export Parting Faces option.

Select K20 as the target part.

Toggle the Free Selection option to the Pick Faces option by indicating the Split Direction. Select the split direction as indicated by the arrow in the picture below:


Select the mirror split direction.

Exit. Select the direction of the arrow as shown in the picture below (to indicate the side to be removed):

The default option is to cut to part with the stitched parting surface. However you may switch this option to Import only without performing the cut.


Select OK.


Core insert

Core insert Step1 We will now create a core insert in the movable side. This insert will contain an instance of a work part and its mirror part.

Display the 4 split direction (core) as shown in the picture below:

Select the Export to Part icon from the Guide.

Change the Export option to Pick Target Sub-Assembly (Export to New Part)


The following options are displayed. You are requested to select the target assembly in which the insert will be created.

Select the Movable side, by clicking its leaf in the tree.


Core insert Step2

Enter a new name to the New part. Click the option marked in the red circle.

Name the new part: Core Insert Left

Change to ISO view. Exit.

Select the two split directions as indicated by the arrows in the picture below:


Select OK.

Activate the newly created part.

Core insert Step3 On the XY plane, create a rectangular. (Using the Sketcher). Select the middle point of the horizontal edge,

and the Layout UCS as indicated by the arrows in the picture below:

Set a 'Same X' constraint.


Select the main assembly UCS as reference point. Set a 'Same Y' constraint to the middle point of the vertical edge and the reference point..

Set dimension as shown in the picture below:


Core insert Step4

Create a New Extrude operation.

We will now attach attributes to the parting faces before exporting them to the Core insert.

First, unstitch the slider split direction in the Work part.

Update the mirror work file. (Associate & Disassociate)


Core insert Step5 Activate the "Local" parting surface part. Create a composite curve as indicated in the picture below:

Create an extend face. Natural - Multi Continuous.


Create a drive face. Select the edge indicated by the arrow below as the section. Select the edge of the parting face as the spine. Select OK.

Create another drive at the second side.


Core insert Step6 Update the Local Mirror part. (Associate & Disassociate.)

Split the face indicated by the arrow, with the highlighted edge as shown in the picture below:


Split the face with the other edge.

Core insert Step7 Update the Local Mirror part. (Associate & Disassociate.)

.

Attach attributes to the parting faces. From the guide, select the icon: Parting \ Parting Attributes. Select the face indicated by the arrow in the picture below:


Attach the face to the cavity (upper split direction) and to the slider split direction.


Core insert Step8 Attach the face in the mirror side (indicated by the arrow in the picture below:) to the cavity and slider split

directions.

Attach the extended faces (including the drive faces) to the core and the slider split directions.


Repeat the same operation on the mirror local part.


Core insert Step9 Select the Export Parting Faces icon.

Show the stock of the core insert, the core split faces and the parting faces.

Select the core insert as the target part.

Toggle the option Free selection to: Pick Faces by indicating the Split Direction. Select the split direction indicated by the arrow in the picture below:


Select the other split direction.

Exit. Ensure that the arrow is pointing upwards. Select OK.


Core insert Step10

Ensure that the core insert is activated. Select the two parting faces indicated by the arrow, and select Remove Geometry.

Activate K20 in the movable side.


Create a sketch on the top face as shown in the picture below. (Use the boundaries of the core insert as references.)

Select Remove Extrude.(Throught0


Apply rounds on the core pocket. Global Value = 10.

Activate the Core insert. Apply rounds. Global Value = 12.

Finial result: xelerate_MD_final.ctf

xelerate mold project

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