Dual clip mould In the following exercise you will create a full 2 cavity mould of your dual clip mould component.

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1 Dual clip mould 2018 In the following exercise you will create a full 2 cavity mould of your dual clip mould component. The mould is required to be a 2 cavity mould and must contain all the necessary detail associated with a fully functioning mould. All standard mould components are downloadable from the Hasco web site or using the Hasco software on your individual PCs. This will limit the amount of actual modelling required. General instructions Create a folder on you H: drive called surname Clip-mould. Copy any files/components e.g. the mould base, sprue bush ejectors to this folder. Mould base selection procedure Determine the overall dimensions of the core/cavity inserts (and consequent dimensions of a two cavity mould. Determine the mould base cross section dimensions required with reference the HASCO standard sizes. (recommended 246x246) Use a standard fixed have clamping plate (27mm) Determine the necessary cavity plate thickness (make 20/30mm thicker than cavity insert) (66 recommended) Determine the required core plate thickness (make 20/30mm thicker than base of the core insert) (56 recommended) Determine the necessary ejector plate riser height (bearing in the distance the ejector pins must travel in order to eject part effectively). As the component is fairly shallow, a relatively small ejector distance should be sufficient e.g. 20/30mm (56 recommended) Use a standard moving half clamping plate (27mm) Generate the mould base required, then save as a STEP file in the dual clip mould assignment folder. 1

2 Summary of mould base dimensions Mould cross section 246x246 Fixed half clamping plate thickness 27 Cavity plate thickness 66 Core plate thickness 56 Core support plate 36 Risers 56 Moving half clamping plate thickness 27 Having generated the mould you are now ready to open in SolidWorks. This mould will be in STEP format so make sure that files of type setting in the SolidWorks file open dialogue box is set to All files *.* Opening the mould in SolidWorks On opening the mould base assembly, you will notice that the components are not fixed and could quite easily be dislodged. We could move all component and then apply the correct assembly relationships / mates appropriate to the components involved plane to plane, cylinder to cylinder. However, as we do not intend to move or animate any of these components it is sufficient simple fix all components in place. To do this select all component, then right clicking over the components select Fixed 2

3 Creating our two cavity insert. Working with our original solid body version of our clip core/cavity insert Use Insert features move-copy to create a two cavity insert. To keep the origin in the centre it is recommended that you move the move the original solid bodies 35mm to the then copy these same solid body 70mm to the right. Next use the boolean combine command to join the two cavity solid bodies. Repeat again combing the core solid bodies. If they will not join then leave as separate solidbodies. Finally add 10mm fillets so that it can be inserted in a pocket with rounded corners. Lastly insert a 24mm diameter hole at the centre of the cavity block to accommodate the sprue bush. On completing export core and cavity solid as stand-alone parts ready for inserting in the your mould base. Modelling the mould Having downloaded the mould-base you are now ready to make the appropriate modification to accommodate core and cavity inserts and other mould detail. Some of which are:- Cut recesses in the core and cavity plates to accommodate the core and cavity inserts (insert screws as appropriate to secure in place) Cut holes to accommodate ejector pins and add ejector pins of appropriate diameter and length. Cut recess for and insert sprue bush Select an appropriate gating location and model the runner and gate detail. 3

4 Inserting core and cavity inserts Create recesses of appropriate length with and depth to accommodate a pair of core/cavity inserts. Next insert your core / cavity inserts into the mould. Cut additional holes to accommodate sprue and insert sprue bush component. Adding ejector pins Just as cutouts can be created at part level, they can also be created at assembly level. This is convenient when we want cut through several plates at the same time. This is ideal for the ejector pins. To create the ejector pin holes we will hide the ejector plate (see arrow), then start a new sketch on the ejector retainer plate. (grid for illustration purposes only). To facilitate this switch the wireframe mode. We will require 5mm diameter ejector pins (approximately 130mm long adjust later to suit). To position the ejectors, turn to wire frame and set viewing direction to look along the axis of the mould. Draw 4 5mm diameter circles in the position shown. 4

5 By rotating the view slightly, it will be clear that these circles are on the sketch plane some distance from the component. Using assembly features, extruded cut create a cut-out with these circles up to the bottoms of the bosses. Assembly sketches are listed after the assembly mates folder. On examining this ejector pin it will be seen that the head is and 10mm diameter 3mm deep. We therefore also require a counter-bore diameter 10mm by 3mm deep to accommodate the head of the ejector pin. Unlike part modelling where the resulting geometry depends on the modelling sequence assembly is not sequential. Therefore if we insert anything into these holes these will also be cut by the assembly level cut-out feature. We therefore need to go back and modify the cut-out and indicate explicitly which plates we want to have cut by this cut-out. Select the original extruded cut and modify its properties. In this dialog you have two options. All components Selected components o Auto select o Manually select All component means cut all components. i.e. Every component in the path of the cut-out will be cut. Selected components means cut specific components. This may be determined by auto selection where it cuts all components it comes in contact with at the time of creation or we can manually select specific components we want to cut. We will manually select the components to be cut. 5

6 Right click on the cut feature at the bottom of the assembly tree. Choose selected components, manual select and pick the plates shown. The ejector pin may now be inserted and should look as shown. Create the cut-outs for the remaining ejector pins and insert ejectors pins as required. There is a further option of Propagate feature to parts is also available. This determines whether or not these features/or cutouts are visible at components level. As we are only creating an assembly drawing we do not need to propagate the cuts to the individual components. This means the holes are only visible at assembly level and will not be visible in the individual plates when opened in part mode. Next insert the sprue bush. Examine the sprue bush supplied and create cut-outs of appropriate size. Once the cut is created and the sprue bush in place your mould should look like this. Now that the sprue-bush in place we can now cut the runners and gates. Finally add runners and gates, again as an assembly level cut-out. Extruded and revolved cuts required. Finally, document your work in a drawing of the assembly using section and detail views to highlight details in your design. 6