Injection Mold Design Using Autodesk Inventor Tooling
Injection Mold DesignUsing Autodesk Inventor ToolingBrian Sather – Autodesk, Inc.MA222-1This class will walk attendees through the process of designing, analyzing, and validatinga plastics injection mold using Autodesk Inventor Tooling. We will cover everything fromautomatic core and cavity generation to utilizing the built-in Moldflow simulationtechnology and standard libraries of mold components to quickly and effectively design ahigh-quality production mold.About the Speaker:Brian Sather is a Technical Evangelist for Autodesk’s Manufacturing Industry Group. During his time inthis role, he has authored several articles on the use of plastics injection molding simulation software toimprove the design and manufacture of plastic parts and injection molds. His exposure to the manystages of product development and awareness of emerging CAD/CAE technologies uniquely position himto present on the topic of design validation and optimization for plastic injection molding. He holds abachelor’s degree in Engineering Graphics, and a master’s degree in Manufacturing Engineering, bothfrom Western Michigan University.brian.sather@autodesk.com1
Injection Mold Design Using Autodesk Inventor Tooling2
Injection Mold Design Using Autodesk Inventor ToolingContentsCreating a New Mold Design . 4Starting a New Mold Assembly . 4Importing the Plastic Part . 5Adjusting the Orientation . 5Setting the Material . 6Analyzing the Manufacturability of the Plastic Part. 7Gate Location . 7Part Process Settings . 9Part Fill Analysis. 10Part Shrinkage Analysis . 11Creating the Mold Core and Cavity . 12Defining the Workpiece . 12Patching Surfaces . 12Runoff Surfaces . 14Parting Diagnostics . 14Generating the Core and Cavity . 15Designing the Runner System . 15Creating the Runner . 15Creating the Gate . 17Adding the Cold Well . 17Inserting the Mold Base. 18Inserting the Mold Base . 18Inserting a Sprue Bushing . 19Inserting a Locating Ring . 19Designing the Cooling System . 20Using a Cooling Channel Sketch . 20Inserting a Cooling Channel. 21Inserting Cooling Components. 22Inserting Ejection Components . 23Inserting Ejectors . 233
Injection Mold Design Using Autodesk Inventor ToolingCreating a New Mold DesignThe Mold Design Assembly file is the top assembly for the mold design. Special template filesmust be used to create the Mold Design Assembly file.In order to see the Mold Design environment and assembly templates you must firstinstall Autodesk Inventor Tooling from www.autodesk.com/ait.Starting a New Mold Assembly1. Create a new mold assembly file usingthe Mold Design (mm).iam templatefile.2. In the dialog box that appears, type inthe Mold Design File Name andLocation.Importing the Plastic Part1. In the Mold Layout tab on the ribbon,select Plastic Part to import the modelinto the Mold Design Assembly.2. Navigate to the folder containing theReciprocating Saw part file and openHANDLE 1.ipt.4
Injection Mold Design Using Autodesk Inventor ToolingAdjusting the OrientationWhen the part is imported it maintains its original alignment and needs to be oriented tocorrespond to the opening direction ( Z axis) of the Mold Design assembly. The cavity side ofthe part should be facing up ( Z) and the core side facing down (-Z).1. In the Mold Layout tab on the ribbon,select Adjust Orientation.2. In the Adjust Orientation dialog box: Change Method to Rotate around AxisX Axis of Rotation – 90 degClick the check markBefore Adjusting OrientationAfter Adjusting Orientation5
Injection Mold Design Using Autodesk Inventor ToolingSetting the MaterialAfter a part has been placed into the mold assembly you can select the material that will beused to manufacture the part. In order to run an analysis (which will be done later) you mustselect a material. The material you want to use can be selected from a list of commonly usedmaterials or from a list of materials after having selected the manufacturer. You can alsoconduct a search of the more than 7,700 plastic materials in the database. Prior to selecting thematerial you can also review the extensive property and manufacturing information of thatparticular grade of plastic.For this example we will be using Cycolac G360, an ABS material from SABIC InnovativePlastics US, LLC designed to be used for automotive applications and power tools.1. In the Mold Layout tab on the ribbon,click Select Material.2. In the Select Material dialog box, clickon the Manufacturer drop-down andchoose SABIC Innovative Plastics US,LLC.3. In the Trade name drop-down, selectCycolac G360.6
Injection Mold Design Using Autodesk Inventor ToolingAnalyzing the Manufacturability of the Plastic PartThere are many factors that play into the overall manufacturability of the plastic part itself. Usingthe built-in Moldflow functionality, analyses can be run to identify the optimal gate location andproper processing conditions that can then be used to perform a Fill analysis that helps identifyproblems in the part design that could lead to manufacturing defects.Gate LocationThere are two options for placing gates on the part: (1) manually place up to 10 gates on thepart by selecting points, edges, or surfaces and then specifying an offset value or, (2) using thesuggest tool to run an analysis that finds the optimal location for up to 10 gates at one time.Often, a combination of both options is used; the suggest option is used to get a general idea ofthe best location for the gate and the manual placement is used to place the gate in an area thatmay be easily accessible for the mold builder or in-line with the type of mold being designed.1. Enter the Core/Cavity environment byclicking the button on the Mold Layouttab in the ribbon2. Then click on the Gate Location buttonfrom the Core/Cavity tab in the ribbon3. In the Gate Location dialog box, pickthe Suggest tab. Leave the Number ofGate Locations at 1 and hit Start7
Injection Mold Design Using Autodesk Inventor Tooling4. The gate is automatically placed at theoptimal location for manufacturability.However, we must also consider thedesign of the runner system 5. On the View tab in the ribbon, turn onthe Center of Gravity and then orientto the Front view. Notice that thelocation where the Sprue will drop isoffset just slightly from the gate. Thiscan be fixed by placing the gatemanually.6. Reopen the Gate Location dialog boxby clicking on Gate Location 1 in thehistory tree. Click on the surfaceindicated in the image to the right andchange the U value to 0.175 and the Vvalue to 0.850. This will align the gateperfectly with the center of the mold.8
Injection Mold Design Using Autodesk Inventor ToolingPart Process SettingsFor the Part Fill Analysis to run, you must configure the part process settings. The settings thatneed to be set are: Mold Temperature and Material Melt TemperatureInjection PressureInjection TimeClamp Open TimeSimilar to the Gate Location, you can either set them manually or use the Suggest tool to runquick analysis to find the optimal settings for the current part design and gate location.1. Click on the Part Process Settingsbutton inside the Core/Cavity tab onthe ribbon.2. In the Part Process Setting dialog box,go to the Suggest tab and check Lowgloss and then hit Start.3. Once the analysis is complete, clickOK on the Summary dialog box toaccept the suggested ProcessSettings.4. You can review and/or adjust yourprocess settings after closing thesummary box by clicking on it from thehistory tree.9
Injection Mold Design Using Autodesk Inventor ToolingPart Fill AnalysisNow that the gate location is set and the process settings have been specified, a part FillAnalysis can be performed. This analysis simulates the plastic filling into the cavity and canprovide a wealth of insight about the overall manufacturability of the part.1. Click on the Part Fill Analysis buttoninside the Core/Cavity tab on theribbon.2. Click Start in the Part Fill Analysisdialog box that appears.3. Once the analysis is complete, a list ofresults appears in the history tree.4. Double click on the Fill time result. Inthe Tools panel, click on the arrow toexpand the list and then click AnimateResults.5. Play the animation of the cavity fillingwith plastic.6. Review the results for Qualityprediction, Air traps, and Weld lines.10
Injection Mold Design Using Autodesk Inventor ToolingPart Shrinkage AnalysisAn inherent property of plastic parts is that as they cool, they will shrink. If this shrinkage is notproperly accounted for in sizing the core and cavity then the molded part will likely come outundersized and out-of-spec. Traditionally, a range of shrinkage values is given by the materialsupplier in the form of % or in/in (or mm/mm). The other option is to run a Moldflow Shrinkageanalysis that will accurately predict anisotropic shrinkage values for the part.1. Click on the Part Shrinkage buttoninside the Core/Cavity tab on theribbon.2. In the Part Shrinkage dialog box leavethe Packing Profile at 10s and 80%.This can be adjusted later to minimizepart shrinkage. Click Start.3. Click OK when the Summary dialogappears to apply the EstimatedShrinkage values to the part.11
Injection Mold Design Using Autodesk Inventor ToolingCreating the Mold Core and CavityAutodesk Inventor Tooling includes a full set of tools for automatically creating the cavity andcore of the mold. The process involves defining a workpiece that will encompass the entire part,defining patching (or shut-off) surfaces, creating runoff surfaces for the parting line, and thenautomatically generating the cavity and core.Defining the WorkpieceTo simplify the modeling process, the Workpiece Definition feature defines one piece thatencompasses the entire part that is later split into the core and cavity halves in a separateprocess.1. Click on the Define Workpiece Settingbutton inside the Core/Cavity tab onthe ribbon.2. Change the X total value to 175mmand the Y total value to 225mm in theWorkpiece Setting dialog box and thenpress OK to create the workpiece.Patching SurfacesPatching surfaces are added to a product to close any openings in the product design for themold tooling design. The patching surfaces define any location where the separation is requiredin the tooling.1. To create the patching surfaces for thesimple holes, click on the CreatePatching Surfaces button.12
Injection Mold Design Using Autodesk Inventor Tooling2. The Create Patching Surface dialogbox will appear listing all the patchingsurfaces to be created. Click OK toaccept and create the surfaces.3. To fill in the opening of the handle, usethe Create Planar Patch tool andselect all the edges of the opening onthe bottom plane of the part.4. To fill in the final opening, open thepart model by right clickingHANDLE 1 in the history tree andselecting open.5. Now use the Boundary Patch tool andselect the perimeter of the opening tocreate a new surface. Close and savethe file.6. Back in the Mold Design Assembly,select Use Existing Surface. Makesure Patching Surfaces is chosen asthe output, and then click on thesurface that was just created.13
Injection Mold Design Using Autodesk Inventor ToolingRunoff SurfacesThe Runoff Surface is the parting surface between the eventual core and cavity in the mold.These surfaces extend from the outer edge of the plastic part to the edges of the Workpieceblock. These are used in conjunction with the Workpiece and Patching Surfaces to automaticallygenerate the core and cavity.1. Click on the Create Runoff Surfacesbutton inside the Core/Cavity tab onthe ribbon.2. Click on all the edges and adjust theX/Y direction of each runoff surfacesuntil the entire boundary is selected.3. Select OK once all edges are properlyselected and aligned to create theRunoff Surfaces.Parting DiagnosticsThe Parting Diagnostics tool evaluates the runoff surfaces and determines if the final runoffsurfaces can be used to split the workpiece. It will also color code the faces of the plastic partthat is defined by the Core and Cavity and return the number of faces for each.1. Click on the Parting Diagnostics buttoninside the Core/Cavity tab on theribbon.2. In the Parting Diagnostics dialog box,click on the Core and Cavity Facesoption and then increase the SurfaceSeparation.3. Click Done in the dialog box whenfinished evaluating the PartingDiagnostics.14
Injection Mold Design Using Autodesk Inventor ToolingGenerating the Core and CavityThe Generate Core and Cavity tool splits the workpiece into separate core and cavity parts. Theworkpiece is automatically split based on the surfaces of the placed part, the added patchedsurfaces, and the runoff surfaces.1. Click on the Generate Core and Cavitybutton inside the Core/Cavity tab onthe ribbon.2. The Core and Cavity are now created.Designing the Runner SystemThe next step in the Mold Design process is to design the runner system. This process involvescreating a sketch of the runner system centerlines and then defining the properties of the gate.Creating the RunnerCreating the runner is a two step process. First, a sketch needs is created using the AutoRunner Sketch or by creating a sketch manually. Second, the Create Runner tool is used todefine the cross section diameter and length and cold slug properties.1. To start the runner sketch, Use theAuto Runner Sketch tool.15
Injection Mold Design Using Autodesk Inventor Tooling2. Select the corner of the workpiecewhere the Core and Cavity cometogether as the base point of thesketch.3. Click OK to finish the Auto RunnerSketch dialog box to enter SketchMode.4. In the Sketch, change the length of theline to 45mm.5. Click on Runner in the ribbon tospecify the runner properties.6. In the Create Runner dialog box,change the diameter to 3mm andselect only the side of the line goingtowards the gate. Then change theCold Slug Position to Start and theCold Slug Length to 0mm and hit OKto create the runner.16
Injection Mold Design Using Autodesk Inventor ToolingCreating the GateWhen you create gates, you have a wide variety of options to create the right shape and size foryour design. Each of the eight gate types selected presents a table of parameters that you canedit to meet your design requirements.1. Start the Gate creation tool by clickingon the Gate button in the ribbon.2. In the Create Gate dialog box, use thefollowing settings: Type: SubmarinePlacement: Two PointsD: 1mmA2: 7.5 degExt1: 0mm3. Select the Gate Location point andendpoint of the Runner Sketch andthen click OK to create the gate.Adding the Cold WellWhen creating a cold well, there are several options available to create the proper size andshape for the feeding system of the mold design. A tapered or annular shaped cold well can becreated and the diameter and length of the cold well can be controlled.1. Select the Cold Well tool by clicking onthe Cold Well button in the ribbon.2. Once the Cold Well dialog is open,select the center point of the runnersketch as the placement. Change theprofile to 3mm wide, 3mm high, and 5deg taper and hit OK to create theCold Well.17
Injection Mold Design Using Autodesk Inventor ToolingInserting the Mold BaseNow that the core and cavity is complete and the runner is designed, a Mold Base can beinserted into the design. In addition to the mold bases, a library of Sprue Bushings and LocatorRings can also be accessed to directly insert these components into the design.Inserting the Mold BaseInventor Tooling has an extensive collection of standard Mold Bases that can be easily insertedinto the mold assembly. Each component of the mold base can be easily customized to suit theneeds of the particular application at hand.1. In the Mold Assembly tab on theribbon, click Mold Base to open up theMold Base selector.2. Using the Vendor and Type drop downlist, choose the DME E mold base andchange the size to 396mm x 446mm.3. For the Placement Ref Point, selectthe corner point where the core andcavity touch.4. Select OK to insert the mold base.18
Injection Mold Design Using Autodesk Inventor ToolingInserting the Sprue BushingThe sprue bushing channels the material into the runner system or directly into the mold cavity,depending on the mold design. It can be positioned so that it aligns with the main runner systemusing two edges of the mold, or by aligning it with the center point of the primary runner.1. Click on the Sprue Bushing tool in theMold Assembly tab in the ribbon.2. Select Sprue Type DME R76 andspecify a -16mm offset.3. Apply these Parameters: D: 18mmL: 96mm4. Click on the center point of the runnersystem to locate the Sprue Bushing inthe center of the mold and then hit OKto insert it into the assembly.Inserting the Locating RingThe locating ring retains the sprue bushing and aligns it with the injection nozzle. When theLocating Ring is inserted into the assembly, it is automatically constrained concentric to thesprue bushing.1. Click on the Locating Ring tool in theMold Assembly tab in the ribbon.2. Choose Type DME R DMEStandard(R 95 SERIE) and specify a-3mm offset. Also change the dparameter to 38mm.3. Click OK to insert the Locating Ring.19
Injection Mold Design Using Autodesk Inventor ToolingDesigning the Cooling SystemThe rate at which the injected plastic cools in the mold has a direct impact on the quality of thefinal product and the manufacturing cycle time. To achieve the quality and productivity required,you need to be able to add the features and components that can help control the temperatureof the mold.Using a Cooling Channel SketchThe quickest way to design the cooling channels is to create a sketch of the overall layout. Thisworks very well when all the cooling lines are on the same plane.1. Create a plane parallel to the partingline with a -18mm offset.2. Open the Manual Sketch tool from theMold Layout tab on th
improve the design and manufacture of plastic parts and injection molds. His exposure to the many stages of product development and awareness of emerging CAD/CAE technologies uniquely position him to present on the topic of design validation and optimization for plastic injection molding. He holds a
which is the mold with availability production hours, including Mold ALC 40, Mold ALC 80, Mold SLDX, Mold ASGR, and Mold PLGD as shown in Fig. 1. Fig. 1. Production Hours of 5 injection molds period April - July 2018 After OEE calculation is applied to the injection mold, and showed that mold SLDX get the OEE values from April- July
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2.3 Part Design Guideline for Injection Molded Plastic 5 Part 2.3.1 Wall Thickness 5 2.3.2 Corner, Fillet and Radii 6 2.3.3 Rib 7 2.3.4 Bosses and Gussets 8 2.3.5 Taper and Draft Angles 9 2.4 Injection Mold Design. 9 2.4.1 Type of Injection Mold 10 2.4.2 Standard Mold Assembly 10 2.4.2.1 Mold Part Name and Functions 11 2.4.3 Cavity and Core 13
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Mold design to manufacture Design and machine the mold in NX Not only does NX offer Mold Wizard to design the complete mold assembly, NX also offers an excellent NC programming solution to set up the machining of mold faces and mold structure components. Feature data added to the model by Mold Wiza
Mold design to manufacture Design and machine the mold in NX Not only does NX offer Mold Wizard to design the complete mold assembly, NX also offers an excellent NC programming solution to set up the machining of mold faces and mold structure components. Feature data added to the model by Mold Wiza
Introduction to Plastic Mold Design 19-3 Figure 19-2 Mold Design interface of Autodesk Inventor Importing Plastic Part in Mold Environment To import a model in the Mold environment, choose the Plastic Part tool from the Plastic Part drop-down of the Mold Layout panel in the Ribbon; the Plastic Part dialog box will be displayed, as shown in Figure 19-3.
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