Mastercam Version 9 SolidsTutorial - Part 8 ppsx

Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 201 8 Designing an Injection Mold from a Surface File In Chapter 7, you imported a solid model for a two-piece injection mold. You then modified the model to complete the design. In this chapter, you will create a two-piece solid injection mold from an imported surface model of a container. You will organize your work using construction colors and levels. You will build on skills that you learned in previous chapters and learn new skills, such as:  Importing a surface model  Solidifying a surface model  Adding draft to solid faces  Extracting surfaces from a solid  Extracting edge curves from a surface  Creating a ruled surface  Trimming a surface to curves  Creating a sheet solid by stitching surfaces  Trimming a solid to a sheet solid  Creating a solid drawing layout Chapter 8 202 Mastercam Version 9 Solids Tutorial Exercise 1 – Importing a surface file In this exercise, you will read an IGES file into Mastercam. The IGES file contains multiple surfaces that represent a container for which you will create a two-piece plastic injection mold. 1. Choose Main Menu, File, Converters, IGES, Read file. 2. Open container-mm.igs from your working folder. The IGES Read parameters dialog box opens. 3. Check your settings against the following picture. Make any necessary adjustments. 4. Choose OK to convert the file. If prompted, choose Yes to delete the current file and fit to screen if necessary. 5. Choose the green Gview-Isometric toolbar button. Your part should look like the following picture. Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 203 6. Choose the Screen-Statistics toolbar button. The prompt area reports the number of surfaces contained in the file. This file contains 27 untrimmed surfaces and 16 trimmed surfaces. 7. Choose Main Menu, File, Save. 8. Enter container-mm.mc9 for the file name and choose Save. Exercise 2 – Modifying the part design In this exercise, you will make several changes to the container to give it its final form. You will add fillets and draft to the Y-shaped standoff in the middle of the part to make it moldable. Once the part design is complete, you will create an injection mold for it. Solidifying the imported surfaces Before you make changes to the model, you will solidify it by stitching the imported surfaces into a single solid. In solid form, the part will be easier to modify. 1. Choose Color from the Secondary Menu. The Color dialog box opens. 2. Set Current color to 7 (light gray) and choose OK to close the dialog box. 3. Choose Level from the Secondary Menu. The Level Manager opens. Chapter 8 204 Mastercam Version 9 Solids Tutorial 4. In the Main Level section of the dialog box, enter 1 for Number and Solidified part for Name. 5. Choose OK to close the Level Manager. 6. Choose Main Menu, Solids, Next menu, From surfaces. The Stitch Surfaces into Solids dialog box opens. 7. In the Original Surface section of the dialog box, choose Delete. Once you have a solidified version of the part, you will no longer need the imported surfaces. 8. Check your settings against the following picture. Make any necessary adjustments. Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 205 9. Choose OK to stitch the surfaces into a solid. Note: It will take several seconds to process this command. The prompt area reports the progress. 10. When the process is complete, check the screen statistics. The system reports that there is now one solid in the graphics window. Note: The gaps between surface edges were smaller than the edge tolerance value (0.075). Therefore, the resulting solid is a closed body, as opposed to a sheet body. You will learn about sheet solids in Exercise 4. Creating an operation history for the solidified part The solidified part is a brick with no operation history. In order to modify the part design, you will use the Find Features function to locate fillets on the model and create an operation based on these features. 1. Choose Find features from the Solids menu (second page). The Find Features dialog box opens. 2. Enter 50.0 for Maximum Radius and check your settings against the following picture. Make any necessary adjustments. Chapter 8 206 Mastercam Version 9 Solids Tutorial 3. Choose OK to find fillets on the solid. The system reports the progress in the prompt area. 4. When the process is complete, Mastercam reports the number of filleted edges it found (in this case, three). Choose OK to clear the message. 5. Choose Backup to return to the first page of the Solids menu. 6. Choose Solids mgr to open the Solids Manager. 7. Expand the operation history of the solid and click on the Fillet operation. Mastercam highlights three fillets located at the intersections of the segments of the Y on the standoff in the center of the part. Note: Drag the Solids Manager away from the part, if necessary, to view the fillets. Decreasing the fillet size You will decrease the fillet size from 6.35 millimeters to 3 millimeters. Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 207 1. In the Solids Manager, expand the Fillet operation and double- click on Parameters. The Fillet Parameters dialog box opens. 2. Enter 3 for Radius and choose OK to close the dialog box. 3. Choose Regen All to incorporate the new radius into the model. Filleting the remaining vertical edges of the standoff 1. Right-click in the operation list of the Solids Manager and choose Solids, Fillet. The Pick Solid Entity menu displays. 2. Toggle Edges to Y and all other Yes/No options to N. 3. Zoom in on the Y-shaped standoff. 4. Select the six vertical edges shown in the following picture. 1 3 4 2 5 6 5. Choose Done to end the selection. The Fillet Parameters dialog box opens. 6. Enter 1 for Radius and choose OK to close the dialog box. Mastercam fillets the selected edges and reopens the Solids Manager. There are now two Fillet operations listed for the solid. Adding draft to the vertical walls of the standoff Currently, the Y-shaped standoff has vertical walls, which are not moldable. You will change the design by adding a 5-degree draft angle to the vertical walls. To save time, you will select one face to draft and apply the draft angle to tangent faces. 1. Right-click in the operation list of the Solids Manager and choose Solids, Draft Face. Chapter 8 208 Mastercam Version 9 Solids Tutorial 2. On the Pick Solid Entity menu, toggle Faces to Y and all other Yes/No options to N. 3. Select the vertical face shown in the following picture. 4. Choose Done. The Draft Face Parameters dialog box opens. 5. Select Propagate along tangencies. 6. Check your settings against the following picture. Make any necessary adjustments. 7. Choose OK. The Pick Solid Entity menu displays. 8. Select the top face as the reference face, as shown in the following picture. The drafted face will hinge at its intersection with the reference face. Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 209 9. Mastercam displays a cone with an arrow on the selected face to indicate the draft direction. Check to be sure the arrow points upward, as shown in the following picture. If it does not, choose Reverse it. 10. Choose Done. The walls of the standoff should now look like the following picture. Chapter 8 210 Mastercam Version 9 Solids Tutorial Filleting edges along the base of the standoff You will fillet edges along the base of the standoff to make the design more moldable. You will select one edge and propagate the fillet to tangent edges. 1. Right-click in the operation list of the Solids Manager and choose Solids, Fillet. 2. Toggle Edges to Y and all other Yes/No options to N. 3. Select the edge shown in the following picture. 4. Choose Done. The Fillet Parameters dialog box opens. 5. Select Propagate along tangencies. 6. Check your settings against the following picture. Make any necessary adjustments. [...]... 12 Mastercam prompts you to enter the point to which you want to extrude the solid Select the corner (endpoint) of the solid shown in the following picture Mastercam creates the block-shaped solid Mastercam Version 9 Solids Tutorial 215 Chapter 8 13 Choose the Screen-Surf Disp-Shading toolbar button The Shading Settings dialog box opens 14 Select Shading active and Translucent and choose OK Your part. .. display in the graphics window Mastercam Version 9 Solids Tutorial 221 Chapter 8 4 Choose OK to close the Level Manager 5 Press [Alt+S] to shade the surfaces 6 Dynamically spin the geometry to view the underside 7 Press [Alt+F1] to fit the geometry to the screen 8 Choose the Delete toolbar button 9 Select the top face, as shown in the following picture 222 Mastercam Version 9 Solids Tutorial Designing... Main Menu, Create, Surface, Next menu, From solid Mastercam Version 9 Solids Tutorial 217 Chapter 8 6 Toggle Solids and Verify to Y and all other Yes/No options to N 7 Position the cursor over the solidified part, as shown in the following picture, and click to select it Select here 8 Choose Next from the Verify Solid Entity menu 9 Once the solidified part (container) is highlighted, choose Done twice... None in the Corners section of the dialog box This option tells Mastercam how to handle gaps that result between entities when offsetting them outward In this case, Mastercam extends the lines until they connect at their endpoints Mastercam Version 9 Solids Tutorial 2 19 Chapter 8 7 Select Absolute in the 2D Contour section of the dialog box Mastercam will offset the chain to the specified depth relative... solidified part (container) is positioned within the solid block 15 Repeat steps 13 and 14 to turn off translucency and shading 16 Save the file 216 Mastercam Version 9 Solids Tutorial Designing an Injection Mold from a Surface File Exercise 4 – Creating a parting surface You have completed the part design for the container and defined the mold stock In this exercise, you will create a parting surface The parting... the container Mastercam Version 9 Solids Tutorial 211 Chapter 8 Creating lines to define the mold stock Before you create the mold stock, you will use the Bounding Box function to create lines at the extents of the container You will add a 24-millimeter margin in the XY directions and a 12-millimeter margin in the Z direction so that the edges of the material extend beyond the edges of the part 1 Open... container boundary 9 When the arrow is positioned outside the red boundary, click to trim the surface The inner section of the ruled surface is deleted 10 Press [Esc] to exit the function 11 Turn on shading Your part should look like the following picture 2 28 Mastercam Version 9 Solids Tutorial Designing an Injection Mold from a Surface File 12 Choose Main Menu, Delete, All, Arcs Mastercam deletes the... top of the part (container) 8 Enter 12 for Distance and check your settings against the following picture Make any necessary adjustments Note: Based on the chaining direction and the offset direction (Left), the system will offset the chain outward, making it bigger 9 Choose OK to offset the selected contour 10 Press [Esc] to exit the function 11 Clear the screen colors 220 Mastercam Version 9 Solids... Clear Center Point 7 Enter 24 for X (Expand) and Y (Expand) 8 Enter 12 for Z (Expand) 212 Mastercam Version 9 Solids Tutorial Designing an Injection Mold from a Surface File 9 Check your settings against the following picture Make any necessary adjustments 10 Choose OK to create the bounding box geometry 11 Fit the geometry to the screen Your part should look like the following picture Extruding a solid... six outer vertical walls, as shown in the following picture 4 5 3 2 1 6 Mastercam Version 9 Solids Tutorial 223 Chapter 8 After the faces have been deleted, your part should look like the following picture Extracting surface edge curves You will extract curves from all edges along the bottom surface (relative to the current view) Mastercam creates a curve (arc, spline, or line) to match the geometry . draft angle to tangent faces. 1. Right-click in the operation list of the Solids Manager and choose Solids, Draft Face. Chapter 8 2 08 Mastercam Version 9 Solids Tutorial 2. On the Pick Solid. the reference face. Designing an Injection Mold from a Surface File Mastercam Version 9 Solids Tutorial 2 09 9. Mastercam displays a cone with an arrow on the selected face to indicate. Mastercam Version 9 Solids Tutorial 211 7. Choose OK to fillet the base of the standoff. 8. Choose OK to close the Solids Manager. Your part should look like the following picture. 9.