Mold and Die casting

8/9/2019 Mold and Die casting

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ZW3DMold and Die Training Guide

（（（（ Only for Prefessional Version&Prenium Version ））））


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Mold & Die V14

Copyright and Trademarks©Copyright 2010 ZwCAD Softw

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ZW3D™ V2010

This documentation may be repro

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esented on the LICENSE

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page 2 Mold & Die V14

Table of Contents

Forward ........................................................................................................................................... 3

Chapter 1 Importing and Creating Geometry ................................................................................ 4

Chapter 2 Analysis, translation, and scaling .................................................................................22

Chapter 3 Creation of Core, Cavity and Parting Planes ...............................................................36

Link Manager ..................................................................................................................................62

Chapter 4 Creating your first insert ..............................................................................................70

Copy Insert to the Core ...................................................................................................................80

Link Manager ..................................................................................................................................81

Chapter 5 Creating your second insert .........................................................................................88

Copy Insert to the Core ...................................................................................................................95

Link Manager ..................................................................................................................................96

Chapter 6 How to create Sliders ..................................................................................................99

Copy Slider to the Cavity .............................................................................................................. 102

Link Manager ................................................................................................................................ 107

Appendix A 2D Drawing Layout ................................................................................................. 109

Appendix B Mold Base Creation ................................................................................................ 116


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The full version of the ZW3Dfrom the ZW3D Help Menu.format directly from the ZW3the ZW3D CD using Windows

This Mold & Die Training Guor print the PDF version, instAcrobat directory) and opendirectory on the CD. Refer toCreating and Editing Parts, Sk

NOTES:1. For best results, view aAcrobat Reader.

2. Since the Mold & Dieit is highly recommendtopics, more informatioand cross-links to relate

3. It should be noted thaprinted or PDF materialthe online documentati

4. ZW3D's Help Interac

simultaneously while yocommands.

Forward

documentation is available online by sou can also browse all ZW3D onlineCD. Go to the "\ZWSOFT\ZW3D 201

Explorer and open the file “ZW3D.chm.”

ide is available as a printed manual andll the Adobe Acrobat Reader (providedhe corresponding files in the \ ZWSOF

he On-line HELP for information relatinetch Dimensions, Constraints, etc.).

nd print the PDF version of the docume

raining Guide is only a portion of the ced that you utilize the On-line HELP.on command options, input options, ad

d tasks and topics.t the On-line HELP will always be m. If you find any discrepancies betweenn.tive Mode allows you to view the

u are working. It will automatically load t

page 3

electing Help Browserocumentation in HTMLEng\doc" directory on

in PDF format. To viewn the ZW3D CD in the

\ZW3D 2010 Eng\PDF g to specific tasks (e.g.,

ntation using the Adobe

mplete documentation,You will find additionalitional command notes,

re up-to-date than anythe two, always refer to

online documentation

opics as you select new


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Chapter 1 page 4 Mold & Die V14

Chapter 1 Importing and Creating Geometry

NOTE: This exercise is done in MM Units. It would simplify things if you were to edit theconfiguration, set your default units to MM and add a default part template calledPartTemplate(MM). You should see this template on the Create new (Part) menu but youwouldn’t have to pick it each time we create a new part object.

Let’s create a Multi-Object file called“Project_554.Z3”.

Create an Part object called“01_IGES_001”.


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Now that we are in the part, wselect Edit on the Utilities tool

The default system tolerance i

The Part settings menu allows

Units – Opti

Show Backedges of the

Alternate Di

openings an

Auto Sew Oby the user a

Whenever yopenings acr

**********NOTE: On the Partrecommended to turn “Auto Sanalyze the geometry after im

can verify what units we will be workingar and then the Preferences option.

0.01 and we will keep that value for thi

us to configure:

n that allows the user to define work uni

acing Edges –Option that allows the umodel as dashed lines or continuing line

play of Free Edges – Option that allow

“Gaps” in the 3D model.

Face Creation – Option that indicates ire automatically sewn to the active mod

u have a Boolean Operation type, holesoss two objects, they can be joined as o

ettings menu, it isw” off allowing the user toorting.

hapter 1 page 5

in. To do that, we will

exercise.

s.

er to see the hidden.

s visualization of

the new faces createdl.

on surfaces ore or kept separate.


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Now, let’s import an IGES file. To do that, select, File and go to Import.

This opens the IGESImport dialog so thatyou can definezsettings for the file thatyou are importing. Wewill select the IGESoption for importing.

In ‘IGES ImportSettings’ it is possibleto define importparameters by

choosing the Set IGESOptions button.

Auto Sew Geometry –Indicates if thegeometry is to beautomatically united.

Rename layercollisions – Renamesthe layers if they

already exist with thesame name.

Remove duplicate surfaces – If there are duplicate trimmed surfaces, the duplicate is thrown away.

Break trim edges - Will analyze the edges of the surface and break the edges on the tangentpoints if needed.

Reset Dependencies - It is not uncommon for third party IGES files to contain incorrectdependency flags causing entities to not import, or to import more than once. Use this option toflushes the dependencies reported in the file, and recreate them based on the entity

references from the parameter section of the IGES file.

Drawings – Import the 2D lay-outs included in the file for the 3D environment.

Bounded planes – Import planes with limits.

Unbounded planes – Import planes without limits.

*********NOTE: For this exercise, deactiveate the Auto Sew Geometry option and select‘OK’ on the Options menu.

Auto activate part – Indicates that afterimporting, the geometry is automaticallyactivated. This command is only necessary if theimporting is done at the object level of the work

session.

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5

3

2

7

1

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5

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Select the Filter settings for i

This menu lets the user define

Select OK.

Select OK and select the file “ \ZWSOFT\ZW3D 2010 Chs\tr

porting. Select the Filter options as sho

the type of geometry to be imported.

ackcover_554_Rev_04.igs”, which is lining installion directory.

hapter 1 page 7

wn.

cated in the


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After you have finished importing the IGES file, the object should look like this:

Your model has all the edges of the surfaces dashed, because they were not sewn during theimport.

The Quality of the imported geometry can be improved by “healing”.

Select the Heal Tool Tab. Select the command Heal Part Topology as shown in the figurebelow.

This command defines the tolerance for correction. Keep the tolerance at 0.01 for now.


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The image below shows some

During the import we deactivaTo do this we need to displayare the tools for the building afor more about each comman

A f

N-Sided Patch: Use thisThe profiles can be wireframeprofiles to define the patch.

Intelligent Blend: Use thinclude the curves, edges, or fOptional inputs include usingcross-sections, sewing, cappin

Set Face Isolines: Use tand V directions of a face. Yo

Explode Faces: Use thisoption to maintain the connectiUse the Sew command to join

Trim to Faces: Use thiswith other faces, shapes, and/

Extend a Face: Use thisthe face. Then select the edge

examples of problem geometry.

ed the auto sew command. Now let’s jthe Free Form Tool Tab as shown belo

nd manipulation of individual surfaces..

w commands are described below.

command to create a face by patching ageometry, sketches, or face edges. Req

is command to create an intelligent blenaces that the new face will start from, gourves, faces or a datum for spine controlg and the ability to give the face a uniqu

is command to set the number of isolinecan also set isolines with the Modify Fa

command to separate faces from a shavity of the explode faces (i.e., they becofaces back into a shape.

ommand to trim away part of a face or sr datum planes.

command to extend one or more edgess to extend and enter the distance to ext

hapter 1 page 9

in the faces using Sew.. The icons on this tab

Refer to the online help

ross 3 or more profiles.ired inputs include the

face. Required inputsto and pass through., circular and conic

name if desired.

s displayed in the Ue command.

e. Use the Group e a separate shape).

hape where it intersects

f a face. First selectnd.


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Select the Sew command.

Select OK to select all faces. You can change the value of the tolerance to be different fromthat of the Part Tolerance. Don’t change it at this time.

Your model should have most of the edges sewn. Do you notice the difference in appearencebetween the sewn edges and the open edges?

Whenever the surfaces are missing or have“Gaps”, the edges will be blue and dashed.

After sewing, the system will give you information about the largest Gap existing on the

geometry. The user can refer to that value to redefine the Sew command using it as the newtolerance. You can use the Heal command again to correct the geometry with the intendedtolerance.

U

We will do this after we are finished repairing the model.

***********NOTE: Since the majority of faces have been joined by sewing, turn the ‘AutoSew’ option back on under ‘Edit > Preferences’.

Suggestions to help determine the scope of the needed repairs:

1. Put your Pick Filter on Shape. Window pick the entire screen.

The message window will report how many separate shapes have been imported.

2. Right-click on the biggest shape that highlights and pick Attributes. Change the facecolor to the darker of the two light blue colors. This way you can visually see the othershapes and it also may give you an immediate idea of how to approach the repairs. You

could also temporarily blank this shape to see what’s left.


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Use the command EDIT > EDThis will find colinear edges aMake this command a regul

Creating the missing surfaces

For the next surface we will uswill also allow us to create a sThese tools are found on the “

For this exercise let’s use the“Trimmed Plane” command.command permits the construof surfaces from 2 or more edand/or curves.Select edges shown in the im to “accept” th

edge selections. again to “finiscommand.

Select the “Fill Gap betedges with a new face”command. Select an opand then Concatenate. OKd combine them into one. r part of your everday Healing

is the next step.

e another command whichrface on the free edges.eal” toolbar.

The bottpocketspart is ssee is aback fac

To verifyas oppo

its normclose towindowat the mFilter mThis willedges foa face is

Thistiones

ge.

” the

een

n edgeto fill

hapter 1 page 11

om faces of theare missing. When theaded, the red face youtually the inside of thee of the part.

that a face is missinged to a face that has

ls reversed, zoom inone of the edges andick the edge and lookssage window. Yourst be set to Edge.give you a count of theund. One edge meansmissing.


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This menu also contains a command which helps us detect problems with the geometry.Select the command “Show Open Edges”. This command lists the number of free edges. Italso displays a form, which allows you to “Zoom To” to better identify the problem area.

Now we will show you how to solve the problem. In this situation we can use the command“Trim to curves”. To use this command, first select the surface to be trimmed. Next select theedges/curves for that trim. (Use the edges shown in the image). Finally, indicate the side youwish to keep.

Face

Edges – Pick 6Keep area


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Trimming a surface does not a

Use the Fill Gap command toThis is shown in the image b

A new surface should be creat

utomatically sew. Select the Sew comm

create the next surface and select an edlow.

ed and automatically sewn per the Prefe

hapter 1 page 13

and, and select OK.

e.

rences setting.


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Find the problem area shown below. Select the Ruled command, for the construction of thissurface. Just select the two edges as shown in the image. Select both edges on the same endto avoid creating a twisted surface. (generally referred to as a “bow-tie” effect)

The Ruled command will not only create flat surfaces, but will also create surfaces supportedby two curved edges. Select the arcs as shown in the image below. This type of surfacecreates straight line rulings between each point on the two curves selected.


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Once again use the commandimage.

After locating the problem, usoptions as shown. Select onethe surfaces from which it origi

Inquire Open Edges to locate the open

the Fill Gap command. Activate all of tof the edges. You will now see a new snated.

hapter 1 page 15

edge shown on this

e available tangencyrface that is tangent to


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Now we are going to repair the surface shown in this image by using the Trim to Curves command.

Select the surface to be trimmed.

(You may have to change the filter toFACE)

Select the boundary edge (use to chain select the edges).

Finally select the side of the face to keep.

Again this surface was trimmed.Sew and select OK


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The next surface will be repairon the Free Form toolbar. SelSelect an extension value of “checked you can skip the next

Now trim the surface to the ed

Guess what?

d by extending and trimming. Use the Eect the open edge of the planar surface.5”. (If you extend the exact distance witwo commands.)

e which will be the boundary.

hapter 1 page 17

xtend Face commandon the right) to extend.h the sew option


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If you verify the openings on the model again, you will see one of two possible results. If afterthe initial sew command you sewed again with the tolerance equal to the largest gap, you willhave a solid with zero open edges......you’re done.

If you did not select that command you will have two edges left that do not match.

To easily repair the fault in the geometry use the Extend faces to close gap between edges command. Just select two of the edges that need repair. The software will only select openedges so you don’t have to be real accurate picking.

If you analyze the model again, you can verify that it is completely closed. However, the modeldoes not have to be completely closed to continue the project in ZW3D.


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Turn on Shade. Change the pi

Right-Click and select Attrib Run the cursor over the edge

Using Blank, Unblank and Smodel that needs to be subtra We can use Combine Shape

Select the mold part as your bremoved.

ck filter to Shape. Run the cursor over t

tes. Change the Face color or select

gain. This will show us that we are still

ap entity visibility you will see that a sted.

with the Remove option as suggested

se. Select the object shown in the imag

hapter 1 page 19

e edge of the part.

K for the default.

issing something.

lid was left in the

in this image.

as the object to be


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To complete the repair on the model we just need to heal by selecting Heal part topology with a tolerance of 0.005.

This will complete the import and repair of your model.

Save your file.


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Mold & Die V14 hapter 1 page 21


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Chapter 2 Analysis, translation, and scaling

After finishing the repairs on the imported part, the next step is to the analyze for draft angleviolations and reposition the model.

Create a new Part at the object level and give it the name “02_Part_Scale_&_Position ”.

Use the Insert Component command found on the right mouse button menu.

The menu will present you with options that allow you to select apart to be inserted on the activated part.

Choose the object “01_IGES_001”

Check the box next to Anchor component

Position it at 0,0,0Remember, you can type ,, or type one zero and hit

on the keyboard.

Zoom All is necessary because the part is not centered on (0,0,0).


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You must use the Merge comso that the object will becomeComponent will become “Reainstance of the component in t

The Merge option is also founhighlighted. (Pick filter should

Let’s analyze the draft angles.

C

and available on the Shape tool tab anlocal. This way the surfaces also belongl Geometry”. The component itself is ne active part is.

on the right mouse button menu whenbe set to All or Component)

Open the new Inquire tool tab.

apter 2 page 23

select the componentto this part. Thet deleted but the

he component is


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By using the Draft Checking mode of the Analyze faces command it’s possible to verify theexisting draft on the 3D model. It also allows us to more clearly see which faces belong to the‘Core’ and those that belong to the ‘Cavity.’

Select the Draft Checking icon from the Required Inputs section and then select the“Direction” option. Now right-click in the graphics window and select the option Face normal.

Select the face as shown in the image. Right-click again picking On Entity and then selectany point on the face.

The default direction is +Z but this part has not been oriented correctly yet.

The optional inputs allow you to vary thedirection and draft angle to verify. For thedraft angle enter 2 or use the slider provided.

The gray surfaces are at exactly 2 degrees.

The green surfaces are OK.

As you rotate the part slightly you will see thesurfaces at the right are purple. Thisindicates that the draft angle is less than 2and these surfaces need repair. You shouldfind 5 on each side of the part including thehole.


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Based on this analysis, we willof the options form.

********NOTE: The display hasin this mode. To change it ba

You will correct the face angle

Select the Draft command froSelect the edges shown on th

C

correct the draft angle of these faces.

been set to Analyze mode. You can cork to Shade mode select View > Shade f

.

the Mold and Die tool tab. Select theimage below on both sides of the part.

Set the angle value to “-2”. Select the toreference plane.

apter 2 page 25

elect OK at the bottom

rect the draft while stillrom the top menu.

ilter option Edge.

p of the ribs as a


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If you analyze the model again at 2, it will verify that the faces have been corrected.

Now change to regular shaded mode.

Save your file.

The next exercise will use some of the Mold and Die tools.


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The first tool we are going to ucreate a block by the maximucreate a datum needed to hel

Select the part and indicate thface used for the draft analysi

This menu shows the maximu

Toggle the Side Increment toround off value. A value of 1 rused for estimating and orderi

Select OK or t

C

se is called Create extruded stock. Thiboundaries (limits or edges) of the part.

in repositioning the part.

flat face as a plane of orientation of the.

m dimensions of the block which envelo

1 and back to 0 to see the values shownunds the numbers to the nearest mm.g material.

o finish.

apter 2 page 27

tool allows you toIt will be used to

block. Select the same

es your part.

. Side Increment is ahis technique can be


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Let’s now create a datum plane on the top face of the block. Later we’ll use this as a referenceposition of the part.

Select the option Insert Datum found on the right mouse button menu.Select the face indicated in the image.Change Z- angle to 180 to get the same orientation shown. for offset of zero.

To place it, select the Origin option found on the menu.Entity filter on ALL

Right-click Critical Right-click Between

Select the two points shown in the image.

to accept the default percentage of 50 to finish the command.


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Finish orienting your part by rotating it on the “Y” axis. To do this we will use the commandMove along direction. Use “0” for the distance value and “180” for the rotation value.

After rotating your part it should look like the following image.

You are only moving the Shape so make sure you don’t window pick with the filter on All.


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Dynamically rotate your viewa point on the geometry (shapThere is a group of tools founduse to measure distances, an

Pi

For this exercise you should sto point as shown in the imag

Specifying the letter A for thFor the Point enter the value “ Select the face indicated in th

You will use the Z componentthe number from the Measure

From t

C

f the part so you can measure the dista).on the Inquire toolbar that you canles, etc... .

k Measure Distance

lect the option Distance > Geometry.

e name of the Variable.0,0,0”.

image. (Narrow face at the lip)

of the distance in the next command. Yo Distance window or use the Variable ‘

he Tools pulldown, pick Variable Brow

apter 2 page 31

ce between a point and

u can copy and paste _Z’ that we created.

ser to see the format.


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After storing the value of the distance on “Z” let’s move the part along the “-Z axis” where youcan copy the value used before.

For the Direction Right-click pick –Z axis

For the Distance either type A_Z (We know this because we looked at the Variable Browseron the previous page)

or Right-click >

Pick the Select Variable icon, then select the A_Z variable

Pick OK

Or


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As shown in the image below,will then move that far along t

C

paste the value from memory into the “De “-Z axis”.

apter 2 page 33

istance” box. The part


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In the next exercise you will scale the 3D model to compensate for shrinkage in the mold. Ascale of 0.6% is suggested. Scale the model using the command “Scale entities” that is foundin the “Tools” toolbar.

Select the Scale entities command. Select the geometry to be scaled.Indicate that the scale is Uniform and then set the scale factor to 1.006.

Pick OK

Save your file.

You are now finished with the editing of this “Part”. Exit this section by using thecommand “Exit part”.


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Mold & Die V14 C apter 2 page 35


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Chapter 3 Creation of Core, Cavity and Parting Planes

Create a new Part named “03_Core_Cavity”.

This new part will be used for core and cavity separation, and will be used in the constructionof the parting faces.


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After you have activated the nthe Insert Component comm

C

w part, insert a component by usingnd found on the right mouse menu as s

Select “02_Part_Scale...” as shSelect the option Anchor comthe coordinates “0,0,0”.

apter 3 page 37

own in the image.

own in the image.onent and locate it at


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After you insert the component perform a Merge so the object can be locally edited. Now thesurfaces belong to this part.

Select the Merge command found on the Shape toolbar. Select the object to be converted.Another way to do this is to select the component, then select the Merge option found on theright mouse button menu.

Select the Attributes > Line menu and configure the thickness of the 3D lines that will becreated by the Parting Line command.

The color will have no affect here because thecolor of Parting Lines is defined in the ZW3DConfiguration. The default is green.

*****Note: In this application whenyou Insert a Component you willalways Merge

Parting Lines will need to be created along theexterior edges forming a closed loop. You willalso need to create Parting Lines around anyholes in your part.


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With the pick filter set to all, silhouettes command. Select to accept all o to finish the c

Save

Blank the part and the Uexterior U filter set to All, select the part

C

ou will create the parting lines. Use thethe “Z axis” as the axis of extraction.the faces.

mmand.

parting lines only by using the Blank co and the outer parting line.

apter 3 page 39

arting line from

mand. With the pick


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Erase the leftover parting lines. We want to erase just the lines, and not the planes so be sureto select the “Parting Line” filter and pick all.

After erasing the unnecessary parting lines, select Unblank all entities.

Create a new parting line around the holes in your part by using the Parting lines from faceedges command.


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Using the command Parting licalculate by picking the two la

Select only the edges as sho

Flat surfaces

5 vertical surfaces

Shift-pick

pick

Again we should have a clo

C

nes from face edges indicate all the ofge flat surfaces and the 5 vertical surfac

n in the image. If you get too many, to delete them.

pick


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Repeat the previous command by and create Parting lines on the edgesshown in the image. Pick the two faces and the two edge loops.

To check for future problems in the Parting lines, select the Check for gaps in parting lines command.

There should be no gaps or overlaps in order for the part to split in the next step.

Shift-pick

Again we should have two closed loops


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ZW3D has two commands to

The command Separsimply select the surfaces to bYou can define a layer for eacEx:

“Z axis” Layer for the“-Z axis” Layer for the

The command DivideSelect all of the lines necessainto two Shapes, select the Sbe divided only on the surface

In this exercise we will use the Make sure the option to separ

You now have two separate sMove – Along a direction (

Save

C

ivide the model.

te into core/cavity regions is used fore separated and indicate the dividing axi of the parts.

ntities belonging to the cavityntities belonging to the core.

faces at parting lines is only used whey for the division of the model. If you wiparate Shape at Parting Line option.and will not separate into two Shapes.

command Divide faces at parting line

te is checked. pick all, <

apes. To temporarily see the results blaxis) select one of the shapes. When

apter 3 page 43

a fast separation. You.

n Parting lines exist.h to separate the objecttherwise the model will

.

iddle-click> twice

nk – shape orour done, Undo.


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Start the construction of a new “Sketch” using the “Datum Plane XY”. This “sketch” will serveas the limit (border) for a parting plane. It will also be used to create the Mold Insert Block.

Your parting face boundary sketch does not have to be fully constrained because we don’tanticipate any changes being made, but just to get some practice we will constrain this sketch.(Can you imagine an engineer saying he doesn’t anticipate changes????) Changes to an

unconstrained sketch may cause unpredictable results.

All new sketches automatically have a “point” at “0,0” and an anchor constraint

Draw a rectangle “center”, centered on the point. Use a width and height value of552/2 or 276. (ZW3D will do the calculation in the text input window.)

The only thing left to fully constrain the sketch is to center the square on the point.

Select “mid point constraint” found under the “anchor” icon.Select two diagonal corners of the rectangle.Select the point at (0,0)

An Alternate method:

There are predefined fully constrained sketches located on the Ready Sketch toolbar.Use the Square. Middle-click to place at (0,0) Edit the width.


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In the next step, we will createZW3D. But first, let’s define a

To create the new face colorsuggested in the image and a

C

After defining your Sketch we can exitoption Exit Sketch found on the rightusing the command on the toolbar.

a parting plane using some of the comew color for the new faces that will be c

elect the command Default surface col ply this as the color.

1

24

apter 3 page 45

the sketch by using theouse button menu or by

ands available ineated.

or. Define a color as

3


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With the Parting Face command ZW3D will automatically create parting surfaces. Select theSketch to which the parting faces will be limited. Next, the exterior (outer) partinglines. Lastly, to skip the interior (inner) parting lines.

In the next step we will join all the surfaces that belong to the Parting plane.

Select the command Sew. This command recognizes all of the surfaces that belong to the“Feature” parting plane. So we need to simply select one of the surface planes.

Envelope

Outer Parting lineShift-pick

Notice the adjoining edges ofthe parting plane are now sewn.


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To complete the parting faces

Select Create fa( It is behind the

This will create mi

Select one face acould for the edge selection because th

“tab” shown right.

ents that you had to pick.

low.

to surface and select the parting linesthe tab.

“10” for the size of the surfaces and “0” f

apter 3 page 47

ff surfaces.

age.

r shutoff. (NOTE: Youere is only one

on the raised tab.

r the angle.


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Select Sew and pick once on the parting faces just created. Don’t just pick OK.

From the orientation shown above you should belooking at the back of the face (pink). Use ReverseDirection if necessary. (probably not)


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Select Create faces at angleon the flat surface.

Change the angle to -10 degr

Select Sew and pick

C

to surface again and shift-pick the ot

es

once on the parting faces just created.

apter 3 page 49

er parting line that lies

OK.


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Use the Combine Shape > Remove operation as suggested in the image.

Save your file

BaseRemove

Result


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Remember the sketch we crea

We are now going to use that

Select Extrude > Base

The Object called “03_Core_ mold. The Core, Cavity and Psame object but now they nee

C

ted before our first set of parting faces?

o create the mold block.

avity” is a working part that contains 3 darting Geometry. Construction of the thr

to be separated into their own object fil

apter 3 page 51

istinct parts of everye had to ocurr in thes.


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Our next step will be to separate the different “Parts”.

Select the command Edit > Copy > Geometry to Part. Set the filter to Shape and start byselecting everything related to the parting planes including the block......

.......Before finishing the command go back and change the filter to Curve, and selecteverything related to parting lines..... HINT: 5 times.


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Middle-click to repeat the com

Give this “Part” the name “05_

C

and to create a “Part” for the ‘core.’

Reference_Core”.

apter 3 page 53


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Repeat the command again to create a “Part” for the ‘cavity’.

Name this “Part” “06_Reference_Cavity”.

After creating the respective “Parts”,

Save

Exit part


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Once at the ZW3D objects lev

Insert the component “04_Parright mouse button menu. Sel Component option.

When you activate this optionFrom this menu you can sele active Part. You can previewby selecting the Preview - Gr

you can be sure you have choyou insert it.

Select the object “04_Partingcomponent to be inserted.

Select the Anchor componen Locate it at the origin point (0, example.

Pick OK.

C

l, select the “Part” “05_REFERENCE_C

ing_Faces” by using act the Insert

new menu will pop up.t a part to insert into thehe parts before insertionphics option. This way

en the right part before

Faces” as the

t option

,0) as shown in the

apter 3 page 55

ORE” and select “Edit”.


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Be sure to Merge the component after inserting it.

Or right-click Merge

Remember, our component is now a shape.

Activate the Mold toolbar and select the Trim plates to core/cavity region command icon.Select the block. Select the core. On the menu that pops up, select the Flip option. all of the surfaces of the parting plane (4). For the copy option select Neither.

You now have a closed solid shape.

Save


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When you have finished the c

At the ZW3D Objects Level, sapply the same techniques th

C

mmand your object should be identical t

lect the “Part” “06_Reference_Cavity” tt were used to define the reference core.

apter 3 page 57

o the image below.

be edited. Now we will


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Insert the Parting Faces component as shown below.

Select Merge. (RMB)

Trim the plates as you just did in theReference Core.


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The next part of the exercisemade to one it is propogated a

Select the “04_Parting_Faces

Blank the block.

Erase the six surfaces shown

C

ill demonstrate how to associate parts tutomatically to the others.

” part to edit.

in yellow in the image (6).

apter 3 page 59

gether so if a change is


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Once you have erased the surfaces on the corners of the parting plane you can rebuild themusing the Drive curve loft command.

This next step will create a single face between the edges. Don’t forget to activate the Smooth option so the connection will be tangent to the ajoining faces.

toolbar

It’s necessary to extend the surfaces so they will exceed the limits of your block. To do that we

use the surface command, Extend, available on the Free Form toolbar as shown in theimage below. Use an extension value of “10”.

Repeat this process to extend the other surface.


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Select the Unblank commandin the image.

We need a method for automareflect these and any changes

The next step will update all th

C

and apply Fillets with a radius of “30mm

tically updating the Reference_Core anmade to the Parting Faces object.

e parts that are associated to the parting

apter 3 page 61

” on the edges shown

Reference_Cavity to

planes.


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Link Manager

Select the ZW3D objects Link Manager found on the Tools menu.

Select Insert and select the objects to be updated. In this case, select the parts“05_Reference_Core” and “06_Reference_Cavity”.

Select Select All.

Check the option Auto Regen to turn it on.

If the user sets up the link manager to do an automatic regen of the Reference parts, eachtime the “04_Parting_Faces” part gets regened, so do the “Reference_Core” and “Reference_Cavity”.

Select Dismiss

You can now run the Regen command. Watch the message window and you will seethat the two reference parts are also regening.


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The ‘reference core’ and ‘refthat we created on the parting

Create a new object with the n

This separator is nothing morevisualize and separate the diff

We suggest you follow this typ

one, using numbers will help t

C

rence cavity’ are now updated accordin plane.

ame shown below. It will be used as a s

than a ZW3D object with a visually uniqrent steps of the project in the Objects

e of naming scheme. Since each part is

o organize your models in the object list.

apter 3 page 63

g to the modifications

parator.

e name. This helps usindow.

based on the previous


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The next step will create a new Part/ Assembly object. This is where you’re going to set upyour mold.

Create a new Part/Assembly object and name it “08_Mold_Assembly”.


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Insert the component “09_Cor This is a new part object so jushown.

This component doesn’t existactivate it automatically for edi

The user knows which file is aon the ZW3D title bar.

In this new object we will creatreference information.

ZW3D automatically creatnew co

C

e_Group” at the “0,0,0” point.

t type the name as

o ZW3D will create andting.

tive. The name appears

e all of the ‘core group’

d, inserted and activated aponent

apter 3 page 65


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The core should be the first object you create in this group. To do that, Insert a newcomponent and name it “11_CORE”. Anchor and Position at (0,0,0).

Once more the system creates a component and automatically activates it for editing becauseit doesn’t yet exist in this project.

Notice that activating the part changed the name of the new object in the title bar and insertedit into the ‘core group’.


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After creating the core object, iPosition as before.

Merge it using the same oper

C

nsert the component “05_Reference_C

tions as before.

apter 3 page 67

re”. Anchor and


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Use the command Exit part to position it in the “08_MOLD_ASSEMBLY” object.

Use the same insert technique again to create the ‘cavity group’.

Insert the component “10_CAVITY_GROUP” into the active object “08_MOLD_ASSEMBLY”.

We will also be creating and activating a new component here. The following is an outline ofthe steps for the cavity side. They are identical to what we just did on the core side.

Insert a new component called: 12_Cavity anchor and position it at (0,0,0)

Insert the 06_Reference_Cavity anchor and position it at 0,0,0 and Merge it.

Now we have an assembly which contains 2 sub-assemblies

08_Mold_Assembly

09_Core_Group 10_Cavity_Group

11_Core 12_Cavity

05_Reference_Core 06_Reference_Cavity

The core and cavity groups will have more components added like inserts and slides but thisshould give you a better feel for what we have done and where we are going.


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Use the command Exit part to

Here you can see the assembl

See the History to verify.

At the ZW3D Objects level yo

C

position the “08_MOLD_ASSEMBLY” o

y of your mold divided by groups.

will see that new objects were added to

Again, notice thenaming structure. Inreality we suggestseparating the groups a

little more than we havedone here. You maywant to use100_Core_Group and200_Cavity_Group anduse numbers in thoseranges.

apter 3 page 69

bject.

the file.


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Chapter 4 Creating your first insert

Select the name “08_Mold_Assembly” from the Object list to edit.

Select the ZW3D “Assembly Manager”, using the right mouse button menu...

********NOTE: At first glance, one may think we are done. We now have what looks like the‘core’ and ‘cavity’ in an assembly. However, there are more parts to create for this mold.

There are a couple of inserts and slides required as well as the geometry used to subtractmaterial from the ‘core’ and ‘cavity’ to accomodate the inserts and slides.

With the Assembly Manager, you can hide, erase, or select a part to edit. You can also doubleclick a part for editing by setting the filter selection to All or Component options.

For this exercise it doesn’t matter so select an edit method for the component“09_CORE_GROUP”.


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If you select the Show Target option again you will see the only things that exist are the threedefault datum planes. You may have to pick this twice. The icon will toggle between Show All and Show Target.

Since this object was created as an empty part, you must insert the component“05_Reference_Core”.

As in previous steps, anchor and position at the “0,0,0” point.

Merge

When you are finished the construction of this insert, the above shape will be trimmed awayleaving you with the insert and the tool used to remove material in the core.


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Now we will add some geomet‘sketch’ should be on the “XY”

*******Hint: Any time you ar twice.

Ch

ry to “13_Core_Insert_01”. Let’s createdatum plane.

creating a sketch on the XY datum pl

pter 4 page 73

n Extrude. The

ane,


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Create a two point rectangle and dimension it from the point located at (0,0).For this “Sketch” use the dimensions shown in the image below.

Exit Sketch by using the right mouse button menu.


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The start value of your extrusiof “50”.

After creating the extrusion, s Save

Ch

on will be the point shown in the image

lect the Shade button. Your object shoul

pter 4 page 75

elow and an end value

d now look like this.


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Hide the core reference, by using the Blank Entities command icon.

Create an extruded boss on the new component.

Add an extrusion. Your “sketch” should be located on the highlighted face shown in theimage.

Reference curves should automatically be created if you set the option in the configuration file.If not, use the following.


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Draw a 2 point rectangle on t

Exit Sketch and complete theend point at the point shown i

Ch

he reference plane with the dimensions

extrusion form as shown. Give it a start the image.

pter 4 page 77

shown below.

value of “0” and an


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“Unblank” so the core reference will be visible.

Create a boolean operation Shape toolbar > Combine Shape between the two entities byusing the Trim Shapes command.

In this command, the Reference Core will be the object for the base and the object fortrimming will be the previously created solid.

Be sure to select the options Flip side to keep and Keep trimming shapes.

2

1


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When you have completed thethe ‘insert’ and the ‘subtracti

As shown in the image above,on the ‘subtraction tool’ that wi

Use the command Face Offse

“0.5”.

Ch

command it should look like the image sn tool.’

you should Blank the actual ‘insert’ andll be used on the ‘core insert’.

t. Select the face indicated in the image

pter 4 page 79

hown. We now have

create a clearance gap

nd give it a value of


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Copy Insert to the Core

After creating the clearance gap, export the geometry. Select the option Edit > Copy >Geometry to Part. Select the shape, and indicate the part for the destination (11_CORE).

Swap entity visibility. This will hide the insertsubtraction tool and make the actual insert visible.


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You need to associate the ‘inswill be updated as well.

Activate the ZW3D objects Liregeneration list.

Regen will regenerat

The part 11_Core is created frcommand. This does not creatcreate a history operation in th

gets changed, the user has tothe latest geometry gets read iautomatic regen of the 11_Codoes the 11_Core.

Reactivate Parent Object so

Ch

Link Manager

rt’ with the ‘core’ so that anytime the ‘in

k Manager and insert the object “11_C

the history of the active part as well as

om the 13_core_insert_01 part with thee a history operation in the 13_Core_ins

e 11_Core part. This means that if the 1

manually go into the 11_core part and pn to the 11_core. If the user sets up the le part, each time the 13_Core_Insert_0

you are in the “09_Core_Group”.

pter 4 page 81

ert’ is altered the ‘core’

RE” into the

1_core.

copy geometry to partert_01 part, but does _Core_insert_01 part

rform a regen so thatink manager to do an1 gets regened, so


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Set the filter to component and the object “11_Core” to activate it.

Use Combine Shapes > Remove, where the object base is the ‘core’ and the ‘subtraction tool’is the shape to be removed.

Base

Remove


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Select the option Show target‘core.’

If you wish to see the objects tthis assembly, use the commaShow More.

Ch

to show only the active object, which, in

hat are on the next level, and not just thend Show More found on the menu Vie

pter 4 page 83

this case will be the

ones that belong to the> Show Scope >


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to open the ZW3D objects editor.

Select the ‘13_Core_Insert_01’, and click Edit.

Right click on Trim1 as shown below and select the option Rollback

from the History Manager.


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Add Fillets each with a radius

Window pick the edges shown

Complete the history replay by

Ch

of “1”

in the image.

clicking the Replay all operations butt

pter 4 page 85

n.


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To change the ‘core’ according to the modification on the ‘core insert’, Edit the “11_Core” andselect the Regen command.

When you analyze your core object you can verify that it’s updated according to the edits you

just made to the core insert.


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Optionally, let’s use the techniinsert’ to construct the second

Don’t forget, that when you crshould be active.

Ch

ues previously employed in the constru ‘core insert’. Name it “14_Core_Insert

ate the second ‘core insert’, the ‘core gr

pter 4 page 87

tion of the first ‘core02”.

up’ “09_Core_Group”


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Chapter 5 Creating your second insert

For the next step of this exercise let’s create another ‘insert’ in the ‘core’. The ‘core group’should be activated first.

Insert a new object component and name it “15_Jiggle_Pin_01”. Anchor and position it at

the coordinate “0,0,0”.

As on previous exercises, we have to insert the Reference core in the active part.


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Merge the ‘core reference’ co

To create the shape of the ‘ins

Create a 2 point rectangle as

Ch

ponent.

ert’, you must first create an Extrusion

shown and dimension it to “0,0”.

apter 5 page 89

n the “XY” datum plane


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Exit the “Sketch” and complete the extrusion with the values shown in the image.

*******Note: Orient the part as shown here before adding draft.

Use the Blank command to hide the ‘core reference’.

Now that we have created the geometry for the head of your insert, we need to add draftangles on the lateral faces.

Use the command Draft and select the filter option Edge. Select the edges as suggested in

the image. For the reference plane, select the bottom face of the insert as indicated in theimage. Also indicate the value of the angle, in this case “-1”. Select Bottom for the Draftside option.

*******NOTE: Because the angle is so small, one way to verify that you indeed do have thedraft applied is to toggle back and forth with the Undo and Redo commands.


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Based on the information shoand apply a “-6” degree draft a

Draft again and apply a “-4” d

Ch

n in the image repeat the same commangle. Use the bottom face as the refere

gree angle to the bottom face as sugge

apter 5 page 91

d on the indicated facece plane.

ted in the image.


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Create a “Sketch” on the bottom face of the insert.

Create the references suggested in the image and create a circle with the dimensions shown.

Right Mouse click > Exit Sketch


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Create an Extruded Boss. T

Fillet with a radii of “3” as sho

Ch

e start value is “0”, and the end value is

n.

apter 5 page 93

“100”.


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Unblank to make the core reference visible.

Erase the bottom face with the pick filter set to face.

Create a trim operation between two entities by using the “Trim Shapes” command.

In this command the object for the base will be the core reference

and the trimming object is the solid created previously.

The options Flip side to keep, Keep trimming shapes and Cap Trimmedregions should be selected.

Result Subtraction

tool

Insert


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Blank t

You now have the tool used t

Select the command Edit >

solid and indicate the destinati

Ch

Copy Insert to the

hide the insert.

subtract material from the core.

opy > Geometry to Part to export this t

on part (11_CORE).

apter 5 page 95

ore

the ‘core’. Select the

Z3


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Link Manager

You can change the workzone by clicking Swap entity visibility. This will hide thesubtraction tool and make the insert visible.

Now, we just need to associate the files of the insert and the core. This way if any change ismade on the ‘insert’ the ‘core’ will be updated as well.

U

Remember, this needs to be done whenyou use the Copy Geometry to Part command.

Select the ZW3D objects Link Manager from the Tools Pulldown and insert the object11_CORE into the regeneration list.


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Exit part until you ar

Set the filter to component a

Ch

in the “09_Core_Group” object.

d the object “11_CORE

apter 5 page 97

” to activate it for edit.


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You need to do a Combine Shapes > Remove where the base shape is the ‘core’ and the‘subtraction tool’ is the shape to be removed.

Show Target

Your part should look like this.

As an optional exercise, create another ‘insert’ named “16_JIGGLE_PIN_02”.

After the final construction of the two ‘inserts’ your ‘core’ should look like this.


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Chapter 6 How t

To create slides that belongs

Create a new object anchore Name it “17_SLIDER_01”

We have to insert the referen

Merge the componen

C

create Sliders

o the ‘core group’ we should edit the “0

and positioned on the coordinate “0,0,

ceU

cavityU

into the active part “17_SLIDE

t to make a shape.

apter 6 page 99

9_CORE_GROUP”.

”.

R_01”.


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Create an Extrusion. The sketch should be on the XY datum plane.

Create a shape just like the one shown in the image. Dimension it to the coordinate “0,0”.


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Exit Sketch and contin

Use the Trim Shape comman

The base is the ‘reference cacreated is the trim object.

Verify that the three optional ichecked.

C

ue the extrusion with the values indicate

to create a trim operation between the

ity’ and the solid previously

puts shown at the right are

apter 6 page 101

in the image.

entities.


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Copy Slider to the Cavity

Your object should look like the image below.

Blank to hide the front of the ‘slide.’

Let’s export into the cavity the subtraction tool for yourslide. Select the command Edit > Copy > Geometry toPart. Select the solid. Indicate the destination for theexport “12_Cavity”.


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Swap Visibility and l

Create an extension for your ‘Open the Wireframe menu aSelect the options Critical + Cin the image. Select the edge

Insert Sketch as shown in the

C

et’s add some geometry to the ‘slide’.

lide’. You need to create a reference pod select the Point command.enter of Curvature from the right mousn which to locate your point.

image. Up uconcof asketc

Nowproje

just i Use t

pickinser

Pickarro

apter 6 page 103

int.

button menu as shown

til now we were notrned where the originketch was whenhing on a face.

we want the origin to bected from the point weserted.

he Origin option and

he point entity weed in the last step.

he line indicated by thefor the UP direction.


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Draw the sketch shown below.

Exit Sketch


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Extrude using the Add option,If your sketch was drawn corre

Create a draft angle for your sl

You’ll need to create an Extrusketch. Select the Up optionbelow. The sketch should be

C

with a start value of “0” and an end valuctly this seam will disappear.

ide.

ion using the Remove option. to create a newt the edge indicatede.


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Create a reference curve on the three edges in the upper left of the part.(one horizontal and two vertical)Create a line as shown. Use the suggested dimensions.

Use the command Trace Profile to create a curve. Select just the three entities that you wantto see.


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Exit your sketch. Compl“0”. End it on the point

Use the Link Manager again tis regened.

Exit part to go to the “

Here we can analyze all the o

C

Link Manager

ete an extrude using the remove option shown in the image.

o force the 12_Cavity to automatically re

09_Core_Group” object.

jects that belong to this group.

apter 6 page 107

with a start value of

gen any time the slide


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Once you are in the main assembly of the mold, set the filter to component and the object “10_CAVITY_GROUP” to activate it.

on the object “12_CAVITY” to activate it.

Combine Shapes > Remove operation where the base shape is the cavity and the slide tool is the shape to be removed.

As your final (optional) exercise, create a second slide forthe mold.


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Appendix A 2D D

In this new chapter we will cre Create a NEW - Drawing ShSelect the drawing sheet temp

These sheets can be configuris located in the .\User-14.00\rtemplate files. Templates_IN.the question when you enteretemplate file. See the Files ta

Appe

rawing Layout

te 2D drawings based on the 3D object

et object.late. You can accept the automatically-s

d by the user. The Template file that hsource directory. Starting with version

Z3 and Templates_MM.Z3. DependingZW3D the first time, you are using eitheof the ZW3D Configuration.

dix A page 109

previously created.

ggested name.

lds all of the definitions3 there are twoon how you answeredr the inch or metric


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Appendix A page 110 Mold & Die V14

Before beginning to draw, look at the ZW3D configuration.

See the Color tab and Display tab. Don’t change anything yet. Review thecolor settings for anything related to 2D geometry. The display tab definesglobal settings for line thickness.

Now cancel.

Select the Attributes pulldown menu.

The first option we will look at on this menu is a line-type configuration.

Here the user can override the attributes set in the configuration of new linesthat will be created.

This will be in affect for any sheet created during the currect session.

If you wish to alter any existing entities select the Attributes option from themiddle or right mouse button menu. This option will activate the same menu asshown above, but it will only affect the selected entities.

You can also keep these settings for later use by ‘Saving a Bundle’. Seethe On-line HELP or try it yourself.


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Another option available on ththe configuration of the dimenintuitively configure the aspectdrawing.

Other menus are used to definHatch pattern that should be

These configurations can be dand Templates_MM.ZW3D fildrawing sheet, and since eve“template” the software will asthat were previously defined.

Appe

Attributes menu allows forsions. Here the user canof dimensions to apply to the

e the text style and the type ofpplied to sections.

one in the Template_IN.ZW3Ds as opposed to a singley new project is based on theume the new configurations

dix A page 111


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The last option available on this menu changes the properties of the 2D views that are createdfrom the 3D objects.

Here the user can define ways of representing the views: hidden line or shaded, scales,aspects of lines, “layers” etc.


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As a first exercise select the cshown in the image. This comyou create 3 or 4 views of themodel, redefine the parameterconfigured by default, and inditype of projection intended—a

Select “11_CORE” as the objefinish.

Your first drawing should look

After creating the views it’s podesired views and right mouse

You can also use this menu toview and change the hidden li

Appe

mmandmand letselected

sate the

1 degree angle or a 3 degree angle.

ct to be used in the 2D views. Click OK

like this.

sible to change their position on the dra click Move. Select the starting point an

alter the attributes of the selected viewes attribute from dashed to Ignore.

dix A page 113

r to

ing. Just select thethe destination point.

. Select the isometric


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For the next exercise you’re going to create different types of sections. You can choosebetween simple sections showing the cross section only and sections showing a hidden lineview of the entire part with the sectioned volume removed.

In the Section command indicate if you want to create a simple Sect Curves or aTrimmed Part section type.

Create the detail views. In ZW3D there are three types of details.

Create a circular detail from one of the sections shown in the previous image. Give this ascale of 4.


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Add dimensions using the Rig

So the final result of your proje

Appe

t Mouse Button menu.

ct should look like the image above with

dix A page 115

dimensions.


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Appendix B page 116 Mold & Die V14

Appendix B Mold Base Creation

The first time you pick this icon you will get the old Mold Base menu. This has been

discontinued but is here only temporarily while we transition to the new Mold Expert software

from Antares.

Save your file and click on the Applications pulldown menu.

Click on Install Mold Expert

The messages above will be displayed in the message window and you will have to restart

ZW3D.

Start ZW3D and open a file.

Click on the User pulldown and select MoldExpert


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Click on the Mold Base ico

There are two versions. Ba

functionality that we had in t

additional cost. You will pro

icons on your screen are ha

commands are included in t

Click on the Configuration

for the Advanced version.

MoldExpert has its own HE

The following is an outline o

Appen

shown above.

sic gives you the same

he old software at no

bably notice that some

zed out. Those

he Advanced version.

icon to obtain a license

LP.

f the steps to get started:

dix B page 117


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Open a new part object for your MoldBase Assembly.

Insert Component Core 11_CoreInsert Component Cavity 12_Cavity

Component Merge ... pick both components --- --------

These need to be shapes at this point

Insert the MoldBase

The Frame will typically be the XY datum.

Either type XY or pick the plane from the graphics area.


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The bounding box option allo

select the appropriate mold ba

Select the button highlighted a

You will have 3 options for def

shapes, select two diagonal cr

The “Extra X and Y sizes” are

etc.

You can accept this size or co

Select OK The moldbase wi

The plates are “shapes” and t

can work on the plates.

Appen

s you to pick geometry which will be use

se size. You can think of it as an envelo

bove

ining the bounding box. You can pick th

itical points, or enter values.

o give you space around the core and c

tinue to edit the sizes that were selecte

ll be inserted.

e other hardware are “components”. It i

dix B page 119

to automatically

e.

core and cavity

vity for cooling lines,

.

done this way so you


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Typically the next step is to subtract material from the Plates to accomodate the core and

cavity.

Extrude aU

BaseU

Shape using the Right-click “Insert Curve List” option.

the entities that make up the top edge of the cavity.

Start at 0End at

Combine shape remove from the 2 plates.


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Before we insert some screws

We are going to insert 4 identi

While we have this menu ope

If you don’t have access to all

You can also select the catalo

box.

Appen

let’s look at the configuration tool.

al screws so check the option, “Retain l

let’s look at the Catalogs tab.

the moldbases listed you can subtract so

that you use the most. If it is the only o

dix B page 121

st used values”

me from the visible list.

ne you use, check the


124/124

Pick the “Standard Elements” icon and we are going to insert 4 socket head cap

screws to hold the cavity to the top plate.

The point will be the critical center of the four radii on the cavity.

Repeat this for the other three.

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Mold and Die casting