How to make a mold in SolidWorks v2001Plus

Prepare files

 

(A) In a UNIX window type /dept/aml/bin/init_mold_SW

This will create a directory called aml-molds in your root directory with all the

mold templates in it

 

*NOTE If you are using the smaller “insert” mold base, the command is

/dept/aml/bin/init_insert_SW

 

OR

(B) Download the zip file of mold parts from the AML webpage and \ unzip into a new directory

Copy all your part files to this directory

 

            *NOTE If you have to create multiple molds, be sure to create individual directories for each one, as the mold templates get altered.

 

Making Mold Plates

 

Start SolidWorks

Create the interim assembly

            New->Assembly

 

Cavity Assembly

 

Begin the mold with your first part

            Insert->Component->From File

            Choose the mold “insert” (mold_workpiece.sldprt)

            Assemble the part w/ respect to the default datums

 

            *NOTE the moving side of the workpiece has 2 circular cutouts in the corner

                        the intersection of the 2 datum planes represents the sprue location

 

Assemble your part into the mold “insert”

            Insert->Component->From File

            Choose your part

 

*NOTE align the desired parting surface of your part with the main_parting_pln datum plane

 

            Use mate, align to assemble the two pieces

 

*NOTE Align constrains 2 planes to face the same direction

                        Anti-align constrains to planes to face each other (opposite directions)

                        Distance provides an offset between 2 planes

 

To add additional parts to the mold, insert them similarly to the first part

To adjust the location of parts (change offset dimensions)

            Right click the appropriate relation under MateGroup

            Edit Definition

 

Modify Mold Part

 

Right click on the insert (in graphics area of FeatureManager)

Edit Part

 

Change part into cavity

            Insert->Feature->Cavity

            Select design part

            Scaling

Increases dimensions of part due to plastic shrinkage

                        Enter the shrinkage value based on your plastic in cavity dialog box

                        Scaling is uniform and about component centroid

            (ex: for .7% shrinkage, enter 0.7)

 

Create Runners in the mold

            Sketch and extrude runners in the mold insert

Runners used in AML typically have circular cross-sections, are on the parting

line, and are standard diameters (1/8”, 1/4”)

            Gates (which you don’t need to include in the CAD) are typically 0.03-0.05” long

 

Close everything and SAVE!

 

Parting Surface

 

Open the mold workpiece

Create your base surface

            Insert->Surface->Offset

OR sketch a line and extrude to a surface

                        OR sketch/create a plane and Insert->Surface->Planar

            Create the flat surface where the two mold plates will meet

 

Create additional surfaces for any protrusions/holes on your mold plates

            Insert->Surface->Offset           with a 0.0” offset

                        OR Insert->Surface->Copy

                        OR Insert->Surface->Fill

                        OR Sketch the surfaces

 

Combine all these surfaces with the base surface

            Insert->Surface->Trim

            Select Mutual Trim                   this will trim the surfaces and knit them together

Choose which sections of each surface to keep

 

 

 

 

Create mold halves

 

Split the “insert” into two pieces

            Insert->Feature->Split

            Select your parting surface

            Name and save each component (moving and stationary)

 

Create a new configuration of the mold workpiece without the split

            Roll the workpiece back to before the split

            Click on the ConfigurationManager Tab

            Right click the workpiece and Add Configuration

            Choose a name <unsplit>

 

SAVE!! and close everything

 

Open the Cavity assembly

Right click workpiece

            Choose Component Properties

            Change the Named configuration to <unsplit>

 

Assembling Components

 

Moving Assembly

 

Retrieve the moving mold assembly

File->Open

            full mold assembly is called moving_mold.sldasm

 

Assemble your new “inserts” into full assembly

            Insert->Component->From File

 

Ejector Pin and Core Pin Holes

 

Create holes in appropriate plates for necessary pins

            Insert->Assembly Feature->Hole->Wizard

            Create a Hole Series

                        All holes are through all

                       

*NOTE

All pins go through moving mold plate and moving ear plate

            Ejector pins and core pin sleeves go through ejector retainer plate only and get

counterbored in ejector retainer plate

            Core pins go through all plates and get counterbored in core pin plate

            Holes in mold plates are to size (1/4” pin gets a 1/ ” holes)

            Holes in other plates are 1/64” oversize (1/4” pin gets 5/64” hole)

            Dimensions of standard pins can be found in the DME catalog (or www.dme.net)

                        Ejector pins, core pins              EX series

                        Core pin sleeves                       S series

                        Return pins (typ. ½”)                74xx series

 

Stationary Assembly

 

Retrieve the moving mold assembly

File->Open

            full mold assembly is called stationary_mold.sldasm

 

Assemble your new “inserts” into full assembly

            Insert->Component->From File

 

Full Assembly

 

Your completed mold should now be represented in full_mold.sldasm

A drawing is also available as full_mold.slddrw

            You should add any relevant dimensions of you cavity

 

Cooling Lines

 

Cooling lines should be created in the Moving assembly and Stationary assembly, after the ejector pin holes are finished.

Cooling Paths are typically “U” or “A” shaped and enter the mold from the bottom.

Keep 1/8” clearance between cooling lines and any holes or cavities in the mold.

Cooling lines are generally ¼” or 3/16” in diameter.