Import the model called -TSPM2003_PSHAPE_Workshop3.

psmodel

Start PS-Moldmaker from the applications menu

Start the Cavity/Core Wizard

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Select the option to Insert core/cavity plates with inserts and then Next

The first phase of the Cavity-Core Wizard allows the user to establish how the split surfaces are built into the tool. The noninserted core/cavity plates option will create the split surfaces directly into the cavity core plates and when the Die Wizard is launched from here it will step through standard plate sizes.

LH_ INSERT_ DATUM

LH_ CAVI TY_ SOLI D

LH_ CORE_ SOLI D

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An insert registration page has now been added to the CCW in order to simplify the naming convention process, this is especially important when adding multiple inserts and slides. Pick each radio button and then select the item in the graphics window associated to this selection

Once the Cavity\Core inserts and workplane are in the selection hit the register button to register the components for use with PSMM

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RH_ CAVI TY_ SOLI D

RH_ I NSERT_ DATUM

RH_ CORE_ SOLI D

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Repeat the process for the RH insert set

Select Next

NOTE: Naming convention are still used in the background :Moldmaker Naming Conventions
SW_COREn (must be used as the solid name for the slide core) SW_WPn (must be used to determine the orientation and origin of the slide mechanism) DW_Cavity (must be used to name the Cavity Insert Solid) DW_Core (must be used to name the Core Insert) DW_WP (is the workplane associated with the Die Insert +Z orientated towards the cavity) DW_Cavity_Plate ( same as DW_Cavity but for the MPD option ) DW_Core_Plate ( same as DW_Core but for the MPD option )

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This next stage of the process allows us to pre-select a supplier for our Mold components, we now have a list of 16 supplier 2 of which are a generic layout that can be used to create custom styles. Select the Hasco catalogue an then Next

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The plates will now be fitted around the inserts and the size of the series (the X/Y plate dimensions) will be selected based on some configurable clearance values for the height, width and length of the plates. If these clearance values are changed then the list of plates will be re-filtered. Set MX to 100, MY to 100 and MZ to 30

The Moldbase can be flipped by 90 degree increments.

Change the thickness of the Cavity Plate to 156 and the Core Plate thickness to 156

The Moldbase tab allows us to establish the size and thickness of the plates. If we switch to using Custom here then the user can enter his own value for the series sizes and change the dimensions of the pillars and screws via the dimensions buttons.

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The Insert/Pockets tab allows the user to position the pockets in relation to the plates. Switch the tab to Inserts/Pockets Change the radio button to position the inserts by D2 and G Set D2 to 65 and G to 0

In this example we need to be more selective as to how we create the fillets so change the Corner Radius to 0 and then hit the Copy to All button

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Switch to the Slide tab and then select Insert a Slide Mechanism button

The first page of the Slide Wizard allows us to create a new core via the Slide Core Wizard register slide core solid that has been modelled manually move onto designing a slide mechanism

Note It is possible to create a slide mechanism by supplying a workplane only providing the workplane is correctly positioned. Its Z axis must be aligned to the intended movement direction of the slide unit and its X axis must be aligned to the direction of draw. Change the radio button to the Register option

To save time slides 1 and 2 (which form the grills on the end) have already been registered.

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Select the workplane positioned in the centre backface of the core as shown above Next activate the select slide core solid radio button and select the slide core solid The workplane and solid can now be registered for use with Moldmaker

Note. Slides 1 and 2 have already been registered. Change the radio button to design slide mechanism

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The second page of the Slide Wizard allows us to establish the slide configuration and switch between working off different mechanisms. Select Slide Mechanism 1 from the list Choose slide type A Next

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As soon as Stage3 of the slide wizard starts the user is prompted to select a slider from the list. The slider required for this demonstration have been provided via a *.xml file. Copy the xml file (UsrDimensions.xml) provided with this document to : D:\dcam\product\PSMoldmaker5440\file\catalogs\generic_metric Note :-PoweSHAPE will need to be re-started for these settings to take effect. When prompted choose the above slide from the list

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Once the slider is selected the slide unit is previewed in the graphics window and the user change any the above parameter to suit the slide design. Change the vertical offset to 5 Click on the image of the Heel Block (Arrowed above). Change the Heel Block Edge Height to 35

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Click on the image of the Angle Pin

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The Slide travel can be calculated by defining the length of the Angle Pin or the length of the Angle Pin can be calculated by the Slide Travel. Set the Day Light to 300 Set the Angle Pin length to 175 Next

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NOTE: The Day Light parameter refers to the open distance between the slider and the cavity plate. This parameter is determined by the movement of the machine and can effect the slide travel calculation, basically if the angle pin is still engaged when the press has reached its maximum opening stroke then the effective height of the pin is reduced.

Set the Length of the Guide Rails to 145 Set the Width to 24 Set the Height to 20

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Activate the Insert a wear plate check box

Select Next

Select Yes thenNext

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Leave the pocket set to Through. Select Slide Mechanism 2 from the Selected Slide Core pull down list.

Select the option to Copy dimensions Copy from Slide Mechanism 1 Then Accept

Select Yes when prompted

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Select Slide Mechanism 3 from the pull down list Next

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Select the above dimension for the slider when prompted

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Pick the Heel Block Image

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Set the radio button to Machine the Heel Block directly Next select the image of the Angle Pin

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Position the Angle Pin on the top of the insert

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Set the Day Light to 300 Set the Slide Travel 15 Next

Set the Length of the guide rails to 75 and the width to 18 Next 98

Set the pocket to be Blind and the Length to be 75 Next

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Increase the Moldbase size to 496x796 to add strength to the back of the Heel Block

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Finally select Finish to complete the process

Creating the Moldbase 101

Deselect the Support plate check box Reduce the Riser Thickness 96

Next

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Next

Finish

Select the Moldbase Wizard from the assistant window

Once the Moldbase has been constructed it is possible to go back into the Wizard and change the parameters (this is currently under preview). We are currently working towards making all the wizards work in this way.

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Change the Riser Thickness to 116 Next

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Next

Finish

Workshop Example 3 Ends Here Adding Mold components

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Adding Ejection Import the model called -TSPM2003_PSHAPE_AFTER_MB.psmodel

Switch the Fixed Half level group off so only the MH components are visible

Enter the component wizard

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Select a Z41 Ejector Pin from the HASCO Demoulding Components list

Un-ticjk trim pin

Select Dimensions

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Select the above dimensions Create

Ejector Pins are automatically locked to the Ejector Base Plate and twin views are now set up to aid the positioning of pins.

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Use the intelligent cursor to position the pin a <-140,95,0> as shown above

Its worth noting that an additional toolbar has been adding for positioning the components using the Bolt command. This toolbar allows the user to flip the alignment, enter a distance and reselect the attachment points.

If you double click the component after positioning it now raises the component positioning form. This allows the user to reposition the component after placement using either another cursor click or entering co-ordinates in the text boxes provided. 109

Double click the component and change its position to 145, 95, 0

Position a second pin at <-145,35,0>

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Position a third pin at <145,95,0>

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Position a fourth pin at <145,35,0>

Hit the ESC key followed by the Select Component button

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Select a Z451 Ejector Sleeve Choose the dimensions 3 (Inner Body) x 250 (Length)

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Looking down the plan view position 4 off Ejector Sleeves to the centre of the 4 cored out bosses as shown above

Hit Esc and then select another component

Select a FlatEjectorPin from the Hasco catalogue

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Select the dimensions 8x200x1.2x7.5

Un-tick trim pin

Create

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Position the blade in the approximate centre of the rib as shown above (the position import form may be useful here for positioning between 2 corners)

Cancel the Component Wizard and then start the Feature Wizard

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Select the Ejector Trimming option and then Create Quit by hitting the Back button

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Go back into the Component Wizard

Select a Z41 Ejector Pin

Select the dimensions 3x400

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Set the length of the pin to 325 Change the pin function to Core Pin Attach to Bottom clamping plate Set the depth to 10 Un-ticjk trim pin

Re-enter the Feature Wizard

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Select the Ejector Pin Holes option and then Create

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If the option to always ask parameters is selected then the user gets the opportunity to configure the fits and clearances of all the plates that the pins are fitted through. The form is raised once for each different diameter.

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Simulating the Mold

A new simulation option has been added to MoldMaker for simulating the Mold cycle, this will open the tool to a configurable opening stroke and then send the Ejector set forward to the maximum available Ejector Stroke. The user has the ability to stop the simulation at a set height, maybe to take a section view in the open position, and then adjust the position via a slider.

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An exploded view of the Moldbase can also be created here. Click the Done button to exit out of the wizard

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Blank everything except the Core Plate and Core Inserts

Go back into the Component Wizard

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Select a HASCO M16x90 - Z31 Socket Head Cap Screw

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Set the Component to Attach to Core Plate Set the counterbore depth 18 Finally select the Create button

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Once the component has been created it will become attached to the cursor and wait for the user to select a plane or face to lock. Pick the bottom face of the Core Plate, it will turn yellow when the cursor is moved over it and pink when it becomes selected and locked

Set the view to Z Position 1 bolt in each insert as shown above approximately at o < 25,105,0> o <-25,105,0>

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Activate the workplane DW_WP1

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Select the cap screw that is positioned in the LH_Core_Insert and mirror with a copy around YZ, ZX,YZ

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Activate the workplane DW_WP

Select the cap screw that is positioned in the RH_Core_Insert and mirror with a copy around YZ, ZX,YZ

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Start the Feature Wizard

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Select Screw Holes followed by Create

Back

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Cooling Wizard

Start the Cooling Wizard

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Select the Moving Half automatic selection radio butto Next

Set the default parameters as displayed above

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Make sure the principle plane is set to Z Set the Depth to 60 Switch the grid locking button On

Switch the line creation mode to single line

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Set the view to look down +Z Start the first cooling line at approximately 360, 60, 0

End the first line at approximately 340,60,0

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Switch to edits mode

Pick the cooling channel previously created

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Make the hole a through hole

Edit the hole properties

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Make the Keep start and end the same check box active

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Set the principle plane to Y

Select the move plane to point icon and snap to the wireframe of the first channel to align the grid so it intersects 143

Set the grid spacing to 15

Using single line construction mode start the first vertical channel at 150,0,30 and end it at 150 0 150

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Create the second vertical channel at 75,0,30 and end it at 75,0,150

Select the wireframe edits icon and then select the 2 vertical lines Goto general edits via the icon in the Cooling Wizard 145

Create a mirrored copy around YZ

Goto Edits Mode and box select all the vertical channels

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Change the hole diameter to 20 and Accept

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Next select the vertical hole is the Core Plate only

Change the holes to be through holes

Next

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Edit the clearance values

Change the clearance distance to 5

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Check the circuit for collision

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Check the influence of the circuit Deactivate the Show influence check box

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Finally select Finish to complete the circuit

Creating Custom Components Open the model TSPM_Components.psmodel Goto <Tools Options - Assembly Options General>

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Acitvate the check box This model is a component library Accept

The above sets the model up as use as a component library the contents of which can be categorised by setting specific components up with a class or class name.

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The class name for each component is set up via right clicking on the component definition or component assembly and then selecting the set class name option.

The name can be then set and accepted Save and Close the model Go back to the main model and under preview mode select <File Open Component Library>

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Select and Open the TSPM_Components library, if it doesnt appear in the list then you may have to Browse to it Goto o o o Tools Show Component Library Window

Switch the class tab to Hot_Runner

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Click on the Hot_Manifold icon to create the component

X2

Create 2 Bushing_Assemblies

Create 1 Hot_Bush

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Create a Plane-to-Plane relation between the Hot Bushing and Top Clamping Plate using a drag and drop approach. Select the plane at the top of the hot bush and holding down the left mouse button start to move the component Holding down the Ctrl key to anti align the component Move the cursor over the top plane attachment and then release the left mouse button

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Right click and edit the relation just created

Enter an distance parameter of 10 and then close the toolbar

Using a similar approach drag and drop the Hot Manifold component onto the Hot Bushing. Use the coincident plane and line attachment between the top face and centre hole of the Manifold and the coincident plane and line attachment at the top of the threaded portion of the Bushing.

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Using the coincident plane and line attachments on the top face of the Bush Assembly drag and drop the 2 sub assemblies onto the 2 holes on the bottom of the Hot Manifold

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Double click on the Hot Bushing

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Change the Y value to 10 (if the hot runner was correctly assembled then all the components will move in relation to the Hot Bushing)

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Finally right click over the Hot Manifold and then select the option to Modify Parameters (this instance)

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Change the HotTipLeft and HotTipRight parameters to 100 and 100 and then Accept

Drafting The drafting module has recently under gone a number of improvements that include improvement to the Hidden Line algorithm and improvements to the section views. A template called TSPM2003_Tooling_Template.psmodel has been included with this documentation, before proceeding make sure that this has been imported into the database.

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Start PS-Draft

Create a new drawing view

Right click over the view and select modify

Activate the template check box Select the model TSPM2003_Tooling_Template Select the drawing G.A.

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Select the schedule button from the drafting toolbar

Select the Assembly schedule type and activate the view

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Position the schedule box as highlighted above

Create a new drawing view

Right click over the view and select modify

Select the model TSPM2003_Tooling_Template Select the drawing Plan Views

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Right click over the left hand view and modify the view

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Change the view properties to be Hidden and Display Hidden Lines

Create a new drawing view

Right click over the view and select modify

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Select the model TSPM2003_Tooling_Template Select the drawing Cavity Insert

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Create a new drawing view

Right click over the view and select modify

Select the model TSPM2003_Tooling_Template Select the drawing Section

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Draw a staggered line through the left hand view using straight lines only and then convert the lines to a composite curve Take a section view

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We will finish off drafting by creating an assembly plate hole schedule, this can be selected from the Tools menu.

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Before creating the hole schedules its worth noting that there are some configurable options that will determine the holes and hole details that will be included in this drafting, these options are under <Tools-Options-Drafting-Schedule> The Holes to Include option can be set to Normal to the View This will only include holes that are normal to the current view direction At any angle This will include all holes in the current selection regardless of drill direction In addition to the Holes to Include option there is a flag that can be set to Include Pre-Drilled Holes. By default holes that are flagged as Pre-Drilled will be ignored by the schedule template (Pre-Drilled holes are the holes that appear on the standard component, this holes are drilled by the manufacturer of the plate).

Finished

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