Vero Visi Mould Tutorial

(1)

VERO UK TRAINING MATERIAL

(2)

INTRODUCTION

Pre-requisite

It is important that before you attempt this VISI-Analysis training example; you must have completed and fully understood the previous Design and Modelling and

VISI-Surface Modelling examples.

During this exercise, it is assumed that the user has a basic knowledge of the VISI-Series software.

Object

The following example will highlight some of the required techniques to fully utilise the dedicated analysis functions within VISI-Modelling.

(3)

VISI Modelling – Draft Analysis

Start by opening the workfile: -

File > Open Select the file named “Front Cover.wkf”

The model should look as below: -

The GREEN model will reside on the “Part 1” layer. Part 1 is to be used as the first revision of a plastic component. There will be a second ORANGE model that resides on the “Part 2” layer. The second model represents a second revision of the same component. We will use the VISI-Comparison module to check for the model differences between Part 1 and Part 2.

Switch ON both the “Part 1” and “Part 2” layer to show both models together.

Analysis > Compare

Select the first body - Select PART 1 ( the original GREEN solid model )

Select the body to compare - Select PART 2 (the second ORANGE solid model )

NOTE :

The comparison tolerance value can be changed from inside the compare control panel.

(4)

A new interface will be displayed (shown below)

There are two methods of display for the new ‘comparison’ module.

The ‘Fast’ method allows the user to show all of the faces that are different between the two models to within a single tolerance.

The ‘Accurate’ method allows the user to identify all of the faces that are different between the two models and colour them with up to 5 different bands of colour.

When the ‘Fast’ method is selected, 4 modes of operation are possible: -

‘None’ – The two models are shaded using the two colours. No differences are detected. The user can move the transparency percentage slider to observe the differences.

Comparison detection method

(5)

‘Only common faces’ – Faces that are identical (to within the set tolerance) will be coloured in the ‘common’ colour. Other faces will be coloured first or second colour as appropriate.

‘Partially common faces’ – The models are coloured the same as ‘Only common faces’ above except, faces that have both identical and different areas will be ‘split’ coloured (i.e. Common colour and first or second colour as appropriate).

‘External – Internal zones’ – This mode will activate the internal and external colour selection icons (and disable the basic first and second colour icons). The models will be coloured with the ‘common’ colour and the areas that are different will be coloured using the ‘Internal’ or ‘External’ colour depending upon whether the situation is ‘metal on’ or ‘metal missing’

Apply

Update the display

If ‘Show common zones’ is set, the complete model will be displayed. If this option is switched off, only the different faces will be displayed

Select the ‘Transparency’ option to activate a slider bar. Moving the slider bar will dynamically show both models

Moving the transparency slider bar will display both sets of faces on either model

Vcamtech Co., Ltd 4

Set the detection method here

The comparison tolerance is set here. Differences less than this will be shown as ‘common’ The colours for the first

and second models can be set here

(6)

If you switch OFF the ‘show’ tick box in ‘Common zones’ and update the graphics, it is very quick and easy to see the design changes for the new revision of the solid model.

Now we know what the design changes are, CANCEL out of the comparison module by pressing the “X”. We will continue to use the rest of the Analysis tools and work on Part 2 (ORANGE model).

Switch ON only the Part 2 layer and also make it the current working layer (green arrow).

Analysis > Draft Analysis

Select the model to analyse – Select the ORANGE solid

Select the plane normal – Select the Z axis (confirm using RHM)

After selecting the plane normal a display panel will be presented to the left hand side. Using this control panel it is possible to manipulate the draft angle values

The design changes displayed without the common zones visible

(7)

1. Load default Parameters – This will allow you to load the default angle range values previously defined

2. Save Default Parameters – After setting the default angle range values, it is possible to save the values and recall them for another model.

3. Allows the user to re-select the direction for draft analysis.

4. Update graphics – Selecting this icon will update the display to represent any angle change.

5. Imprint Isocline curves – Selecting this icon

will imprint the edges where each colour band changes onto the model.

6. Imprint Isocline curves and colour face sets – Selecting this icon will imprint the edges where each colour band changes and also maintain the face colours defined by the draft analysis control panel

7. Draw Isocline curves – Selecting this icon will create wireframe geometry where each colour band changes onto the model.

8. WPL by Direction. Will automatically create a new workplane based on the current draft analysis direction.

9. Angles evenly spaced – This option will automatically space the angle ranges evenly. For example, if you choose 8 divisions then the computed angle ranges will be 180°/8 (i.e. 22.5° each) Vcamtech Co., Ltd 6 3 8 4 5 6 7 9 1 2

(8)

IMPORTANT : For this example, it is necessary to switch off the ‘Angles evenly spaced’ option so that we can manually define our own angle ranges.

After defining the angle values select the ‘Update Graphics’ icon.

If we look at the angle ranges defined inside the VISI-Analysis control panel we can see that any faces that are defined using a dark red colour fall between 0 and -1 degree draft. Any faces that are defined using a pink colour fall between -1 degree and -5 degrees of draft.

Using this graphical representation, we can see that the 4 inner bosses are displayed dark red. This indicates that we will need to increase the draft angle for these features.

Click on the ‘X’ to close Draft Analysis Switch off

this Set the angle values to match

the dialogue box displayed.

(9)

Modelling > Draft Faces

Select reference edges - Select all 4 outer edges of the 4 inner bosses (E1)

(confirm using RHM)

Select Draft Faces - Select all 4 cylindrical faces of the 4 inner bosses (F1)

(confirm using RHM)

Vcamtech Co., Ltd 8

F1 E1

(10)

Select the Draft Direction – Select the Z-axis (confirm using RHM)

Enter the Draft angle: -2 (minus)

NOTE !

You will notice if you select the “Preview” button that the draft is added to the cylindrical face and the fillet radius at the base of the boss is also adjusted so it’s tangency condition is maintained.

There are other drafting options available, as your tutor for an example.

(11)

Using the same values as for the first analysis after we select the ‘Update Graphics’ icon.

You will now note, that the boss faces are coloured Pink which now indicates that the draft angle falls between -1 and -5 degrees of draft.

When using the ‘Draft Analysis’ tool there are more options available. These can be activated by selecting the options from the top tab bar.

Isocline

The concept of the Isocline rendering allows you to shade the component using strips of colour that will follow the isocline curves of each surface. Using the control panel it is possible to customise the representation of the isocline strips to produce a better representation of the ‘flow’ of the surfaces.

After selecting the Isocline tab, the left hand dialogue box will change to display the parameters for Isocline shading.

The draft analysis dialogue box updates to show the following interface

(12)

The values represented within your dialogue box, may vary from the ones displayed above. Please change your settings to match the values defined.

After defining the angle values select the ‘Update Graphics’ icon.

Zone colour boxes. These depict the colour of the curves that will sweep the body.

Mode. Here you can decide if you want to generate curves by entering a number or a step angle.

Specify the inclusive angle where you require the curves to be shown. 90 to -90 will cover the whole component.

The step angle is activated when the step button is selected. The Step angle is the increment for creating a new curve along the selected component.

The N.Curves is activated when the number button is selected. The N.Curves is the number of curves to be produced on the component.

The thickness box becomes active when the zebra strip check box is unchecked.

This value sets the thickness of each curve.

Limit at bottom specifies if the curve starts at the top or bottom of the curve subdivision.

Blend shade the Curves

The zebra strip option generates curves of the same thickness.

The Different colours checkbox allows the user to use the additional colours above specifying the frequency of these colours in relation to the leading colour.

If you zoom into the highlighted area you will note that using the isocline rendering it is possible to see a

‘non flowing’ surface. Using the tools available, we

(13)

VISI Modelling – Draft Analysis NOTE !

To modify the ‘non flowing’ surface, it is necessary to exit out of the draft analysis option. Before we remove the problem face, there are other tools we can use to highlight this problem area. In this example we can use the smooth edge option to check the tangency of the connect edges to the problem face.

Click on the ‘X’ to exit the Analyser panel

Analysis > Smooth Edge

The ‘Check Edges Smoothness:’ panel shown on the next page will appear. Use the ‘Select’ icon to start the process of selecting the edges

Select the edges to check for smoothness – Select all 4 edges of the problem face

The dialogue box shows you the number of smooth and non-smooth edges. You can also change the parameters that control how the arrows are displayed.

Vcamtech Co., Ltd 12

Using the face icon will automatically select all 4 edges

Angle threshold is used to define what is acceptable as smooth

Arrow colours used to identify the smooth and non-smooth edge normals.

The number of edge arrows displayed along each edge can be set here Select edges to check

for smoothness _{Shows the maximum}

deviation (in degrees) from ‘smooth’ i.e. zero degrees Shows the maximum deviation (in degrees) from ‘smooth’ i.e. zero degrees

(14)

In this example the system will highlight yellow and blue arrows on 3 of the 4 edges. This indicates that along three of the edges, there are conditions that exceed the accptable smooth condition.

We will now re-build the problem face, check the smoothness of the new face and validate the ‘flow’ using the Iscoline rendering.

Exit the ‘Check Edges’ panel.

Modelling > Delete \ Detach faces

Select the face to delete – Select face 1 (F1)

F1

Ensure that the ‘Delete’ option is set Non-Smooth edge Non-Smooth edge Non-Smooth edge Smooth edge

(15)

Using this function, we will remove the single face from the solid model (automatically converting it to a knitted surface body). It is then a simple case of creating the replacement surface and re-uniting it to the master model to recreate the solid body.

Solid > Other Surfaces > Patch Surfaces

Select the edges to create the patch surface

(i) Select the first edge – Select Edge 1 (E1)

(ii) Select the first edge – Select Edge 2 (E2)

(iii) Select the first edge – Select Edge 3 (E3)

(iv) Select the first edge – Select Edge 4 (E4)

Operation > Unite

To re-create our solid body it is necessary to unite our new patch surface to the existing knitted body.

Select the target body – Select the ORANGE knitted surface body

Select sheet body – Select the new patch surface body

(Accept the default knitting parameters)

Vcamtech Co., Ltd 14 E1 E2 E3 E4 Result of the patch

(16)

With the solid model complete, we can now check the smoothness of the edges and re-run the Isocline rendering to see if we have improved the ‘flow’ of the fillet radii

Analysis > Smooth Edge

Select the edges to check for smoothness – Select all 4 edges of the new patch face

Using the face icon will automatically select all 4 edges

With the new face in place, the dialogue box will display that all 4 edges are now within our smoothness tolerance.

We can now check the ‘flow’ of the new surface using the Isocline rendering

All edges are now considered smooth

(17)

Switch to the Isocline rendering

Using the same values as before, select the ‘Update Graphics’ icon.

Finally, with our model fixed, we will use the splitting tools to create core and cavity.

Analysis > Split Line

Selecting the Split Line option will display the following control panel to the right of the main screen. A description of all the functions available within the Split Line Manager can be found on the following pages. Every option is activated using the icons at the top of control panel.

Each function is modal, which means that after selecting them, they remain active until the ‘ESC’ key is pressed

Smooth flowing condition.

(18)

1. SPLIT LINE

This function allows you to produce the split curve passing through the points having a normal vector of zero degrees to the work plane. The curve is produced and imprinted to produce an edge(s) on the solid. This function will also produce the split line on the edges of the solid.

2. ISOCLINE CURVE

This function produces the isocline curves to an angle and a tolerance set by the user. An isocline curve produced at zero degrees will produce a result similar to that of the Split Line function.

3. IMPRINT ELEMENTS ONTO BODY

This function imprints wireframe geometry on to the selected solid. The imprinted edges are then treated as Split Line edges. This command is very useful when you need to add some curves manually, to achieve the desired split line.

4. SPLIT LINE ONTO FACES

This function will imprint a split line only onto the selected face(s) of a body. The resulting edges are managed as Split Line edges, and therefore visible in the split line tree.

This command allows the user to create a split line on specific faces of a solid, avoiding the calculation on the complete body.

1 2 3 4 5 6 7 8

(19)

5. ISOCLINE CURVES ONTO FACES

This function will imprint isocline curves only onto the selected face(s) of a body using a user definable angle. The edges produced are managed as Split Line edges, and therefore visible in the split line tree.

6. IMPRINT ELEMENTS ONTO FACES

This function will imprint wireframe elements only onto the selected face(s) of a body. The edges produced are managed as Split Line edges, and therefore visible in the split line tree.

7. IMPRINT SHADOW

This function will produce the silhouette edges on the body calculated from a selected direction (e.g.X,Y,Z, or by element). The silhouette produced corresponds to the outer visible boundary of the body from the defined viewpoint (similar to the result produced by a plan view of the solid in the Plot View). The imprinted edges are managed as Split Line edges, and therefore visible in the split line tree.

This function is very powerful because if the solid does not contain undercuts, the resultant silhouette curve will produce the ideal curve for the splitting of the component.

Note that this function may generate some unnecessary edges, especially in cases where a part has some undercuts. For this reason it is possible to refine the results generated by the Imprint shadows with the Search Silhouette function.

8. SEARCH SILHOUETTE

This command can be used to calculate the split line as a first operation, but it requires that the solid already has edges corresponding to the required split line. In this case the edges are identified and managed as split line edges. Therefore if the split line edges do not lie exactly on the edge of a face it is not recognised as a split line edge.

This function is generally used to refine the results obtained from the other split line functions.

When analysing all the edges of a solid, this function keeps only the edges that belong to the silhouette curve and will delete all the others. This is often very useful as the Imprint Shadow function may create some unnecessary or redundant edges. By using the Search Silhouette all the edges that do not belong to the silhouette curve are deleted from the body.

9. EDIT

Using the edit function it is possible to add or remove edges from the split line tree. Any new edge selected will be treated as a split line edge and any existing split line edge selected will be removed them from the tree list. Using this function it is possible to manually remove any redundant edges.

(20)

10. IMPRINT SEGMENT

This function allows a segment to be imprinted between two chosen points on any selected face(s). It is necessary to specify the direction in which the segment will be imprinted. The imprinted edges are managed as Split Line edges, and therefore visible in the split line tree

11. UNMARK BODIES

This function will delete all edges belonging to the Split Line list.

12. UNMARK FACES

This function will remove the Split Line edges belonging to the selected face(s).

13. ANALYSE EDGES

This function will display the edges of the Split Line result in the tree-view

14. ANALYSE FACES

This function will display the resultant faces split with the user defined split line in the tree-view. If only two face sets are present, the splitting simulation can be run using the slider bar.

To activate the graphical simulation it is necessary to view the face sets in shaded mode. It is possible to shade the face sets by clicking them with the right hand mouse button and selecting the shading option from the menu. Moving the slider bar will perform the simulation of the component splitting.

15. APPLY and COLOUR

This function exits from the Split Line manager and confirms the result of the analysis. Any face sets will be coloured accordingly. Re running the Split Line function will read all the edges that were previously created and show them in the tree.

16. DRAW SPLIT LINE

This function will exit from the Split Line manager and produce the split line as wireframe geometry.

17. SPLIT

This function will exit from the Split Line manager and physically split and colour the solid body using the user defined split line

(21)

From within the split line manager select the Imprint Shadow option

Select the body to analyse – Select the solid model

Select the direction – Select the Z axis (confirm using RHM)

The result of the analysis should now be visible within the split line tree. To activate the tree it is necessary to press the ESC key.

Select this body to analyse

Selecting any edge set inside the tree will highlight the edge set within the CAD screen.

Selecting any edge using the right hand mouse button will display the following menu :

Using these options it is possible to remove a set from the list, remove all other sets from the list and also to zoom directly on the highlighted set.

(22)

With only closed sets inside the tree, we can select the ‘Analyse Face Sets’ icon to see the results of our split line.

After selecting the ‘Analyse Face Sets’ icon the display inside the tree will now display only two face sets

With the shading mode activate, it is possible to use the slider bar to simulate the component splitting.

To complete the component splitting, select the Split icon to accept the result.

Congratulations. This completes an introduction to the tools available within the VISI-Analysis module.

Select the Face Sets using the right hand mouse button and select the ‘Goureaud shading with outline’ from the context sensitive Menu :

(23)

VERO UK TRAINING MATERIAL

(24)

INTRODUCTION

Pre-requisite

It is important that before you attempt this training example; you must have completed and fully understood the previous VISI-Design and VISI-Modelling and VISI-Surface

Modelling and VISI-Analysis examples.

Object

The following example has been produced to explain how the Split Line manager can be used and manipulated to produce the ideal component split line. As with many models, there is often more than one way to split a component, so in many cases, different toolmakers will produce a different result.

(25)

VISI Modelling – Splitting

Start by opening the relevant workfile: -

File > Open

Select the file named “split manager.wkf”

Analysis > Split Line

Selecting the Split Line option will display the following control panel to the right of the main screen. A description of all the functions available within the Split Line Manager can be found below. Every option is activated using the icons at the top of control panel.

Each function is modal, that is after selecting them, they remain active until the ESC key is pressed.

1. SPLIT LINE

This function allows you to produce the split curve passing through the points having a normal vector of zero degrees to the work plane. The curve is produced and imprinted to produce an edge(s) on the solid. This function will also produce the split line on the edges of the solid.

Vcamtech Co., Ltd 2

1 2 3 4 5 6 7 8

(26)

2. ISOCLINE CURVE

This function produces the isocline curves to an angle and a tolerance set by the user. An isocline curve produced at zero degrees will produce a result similar to that of the Split Line function.

3. IMPRINT ELEMENTS ONTO BODY

This function imprints wireframe geometry on to the selected solid. The imprinted edges are then treated as Split Line edges. This command is very useful for when you need to add some curves manually, to achieve the desired split line.

4. SPLIT LINE ONTO FACES

This function will imprint a split line only onto the selected face(s) of a body. The resulting edges are managed as Split Line edges, and therefore visible in the split line tree.

This command allows the user to create a split line on specific faces of a solid, avoiding the calculation on the complete body.

5. ISOCLINE CURVES ONTO FACES

This function will imprint isocline curves only onto the selected face(s) of a body using a user definable angle. The edges produced are managed as Split Line edges, and therefore visible in the split line tree.

6. IMPRINT ELEMENTS ONTO FACES

This function will imprint wireframe elements only onto the selected face(s) of a body. The edges produced are managed as Split Line edges, and therefore visible in the split line tree.

7. IMPRINT SHADOW

This function will produce the silhouette edges on the body calculated from a selected direction (e.g.X,Y,Z, or by element). The silhouette produced corresponds to the outer visible boundary of the body from the defined viewpoint (similar to the result produced by a plan view of the solid in the Plot View). The imprinted edges are managed as Split Line edges, and therefore visible in the split line tree.

This function is very powerful because if the solid does not contain undercuts, the resultant silhouette curve will produce the ideal curve for the splitting of the component.

Note that this function may generate some unnecessary edges, especially in cases where a part has some undercuts. For this reason it is possible to refine the results generated by the Imprint shadows with the Search Silhouette function.

(27)

8. SEARCH SILHOUETTE

This command can be used to calculate the split line as a first operation, but it requires that the solid already have edges corresponding to the required split line. In this case the edges are identified and managed as split line edges. Therefore if the split line edges do not lie exactly on the edge of a face it is not recognised as a split line edge.

This function is generally used to refine the results obtained from the other split line functions.

When analysing all the edges of a solid, this function keeps only the edges that belong to the silhouette curve and will delete all the others. This is often very useful as the Imprint Shadow function may create some unnecessary or redundant edges. By using the Search Silhouette all the edges that do not belong to the silhouette curve are deleted from the body.

9. EDIT

Using the edit function it is possible to add or remove edges from the split line tree. Any new edge selected will be treated as a split line edge and any existing split line edge selected will be removed from the tree list. Using this function it is possible to manually remove any redundant edges.

10. IMPRINT SEGMENT

This function allows a segment to be imprinted between two chosen points on any selected face(s). It is necessary to specify the direction in which the segment will be imprinted. The imprinted edges are managed as Split Line edges, and therefore visible in the split line tree

11. UNMARK BODIES

This function will delete all edges belonging to the Split Line list.

12. UNMARK FACES

This function will remove the Split Line edges belonging to the selected face(s).

13. ANALYZE EDGES

This function will display the edges of the Split Line result in the tree-view

14. ANALYZE FACES

This function will display the resultant faces split with the user defined split line in the tree-view. If only two face sets are present, the splitting simulation can be run using the slider bar.

(28)

To activate the graphical simulation it is necessary to view the face sets in shaded mode. It is possible to shade the face sets by clicking them with the right hand mouse button and selecting the shading option from the menu. Moving the slider bar will perform the simulation of the component splitting.

15. APPLY and COLOUR

This function exits from the Split Line manager and confirm the rusult of the analysis.

Re running the Split Line function will read all the edges that were previously created and show them in the tree. The face sets are also coloured accordingly.

16. DRAW SPLIT LINE

This function will exit from the Split Line manager and produce the split line as wireframe geometry. The face sets are also coloured accordingly.

17. SPLIT

This function will exit from the Split Line manager and physically split the solid body using the user defined split line. The face sets are also coloured accordingly.

From within the split line manager select the Imprint Shadow option

(29)

As explained in the initial description of all the split line manager options, in some cases, redundant split line edges are produced. In this instance it is recommended to use the

‘Search Silhouette’ option to refine the results obtained from the other split line functions.

From within the split line manager select the Search SIlhouette option

Vcamtech Co., Ltd 6

Selecting any edge set inside the tree will highlight the edge set within the CAD screen.

Selecting any edge using the right hand mouse button will display the following menu :

Using these options it is possible to remove a set from the list, remove all other sets from the list and also to zoom directly on the highlighted set.

(30)

Select the option to ‘Delete Redundant edges’

You will now see that the result has changed. The 6 closed sets are the bottom edges of the windows on the 6 outer bosses. The 8 open sets are a mixture of edges around the outer and inner split line. Selecting each edge within the tree will highlight the relevant edge on the CAD screen.

Within this example there are some edge sets that are not required. These can be removed from the list by selecting inside the tree.

Select ‘Open Edge Set 7 & 8’ using the right hand mouse button.

Using the context sensitive menu, select the ‘Unmark Set’ option. This will remove this edge set from the tree

(31)

VISI Modelling – Splitting Note!

If Set 1 was Unmarked the other open edge sets move up one place, i.e. set 2 becomes set 1 etc.

i.e. You need to keep sets listed as 1 and 2 only set 7 & 8 needs to be unmarked.

Note that some edges are very small. It may be necessary to use the ‘Zoom In’ option to display the edge(s) before removing from the set.

The result of unmarking the redundant sets should leave six open sets:

Selecting each open set individually will highlight that together they almost complete the split line around the outer edge of the component. The requirement for a split line is to produce a closed set around the complete part.

On this model the result cannot be achived automatically as a closed set because there is a very slight undercut (where the two sets appear to meet).

For the purpose of this training example we are going to ignore this small area and use the Split Line Manager tools to join the two open sets together.

From within the tree, highlight ‘Open Set 1’ and select the ‘Edit’ icon.

Vcamtech Co., Ltd 8

(32)

Selecting this option will activate the edge selection. To join the two open sets together it is necessary to select the edges that will connect the two sets together. During the selection process, it is also possible to select existing edges (redundant) and these will be removed from the tree.

NOTE:

After performing this process on both sides of the component, four open set still remain.

Selecting “Set 1” in the split line tree will highlight that the split line has an extra edge selected that is not required to create a closed loop around the component. Zoom into the area shown below to unmark the selected edge.

New connecting edge

Redundant edges

Open Edges that need to be Unmarked to create

(33)

At this point you will still have four open sets.

Using the skills you have been shown up to this point investigate the open sets you have left and select the missing edges to create a single closed loop around the component.

If succesful, joining the four open sets will produce a closed set and the split line tree will only display closed sets.

With only closed sets inside the tree, we can select the

‘Analyse Face Sets’ icon to see the result of out

split line.

After selecting the ‘Analyse Face Sets’ icon the display inside the tree will now display only two face sets

Select the Face Sets using the right hand mouse button and select the ‘Goureaud shading with outline’ from the context sensitive Menu : Double click on Set 1 to expand the tree

Selecting “Open Edges” using the right hand mouse button will display the following menu :

Using the Unmark option it is possible to remove the final two Open Edges.

(34)

With the shading mode activate, it is possible to use the slider bar to simulate the component splitting.

To complete the component splitting, select the Split icon to accept the result.

Congratulations!

This completes the ‘Split

(35)

VERO UK TRAINING MATERIAL

(36)

INTRODUCTION

Pre-requisite

It is important that before you attempt this Core Modification training example; you must have completed and fully understood the previous VISI-Design and VISI-Modelling and

VISI-Surface Modelling and VISI-Analysis examples.

Object

With the following example we will try to simulate a real scenario where a core and cavity model has already been created from an imported model when a design change appears. Within this example we will use the VISI-Analysis tools to highlight the design changes and then to apply the modification to the existing core model.

(37)

VISI Modelling – Core Modification

Start by opening the workfile: -

File > Open

Select the file named “Core Modification.wkf” The model should look as below: -

Within this example each model has been located on a separate layer. You will find that there are 4 layers. At the beginning of this tutorial we are only interested in the original component and the imported part revision. These two models can be found on the ‘original component’ and the ‘component revision’ layer.

NOTE !

To run the model comparison it is necessary to select both bodies (solids or surfaces). In many cases the models look identical as the changes are slight and often not easily recognisable. For this reason it is recommended to have a different colour for each model; it is then possible to select each body using the colour filters.

(38)

Analysis > Compare

Select the first body - Select PART1 (the original solid model – light green)

Select the body to compare - Select PART2 (the revision solid model – pale yellow)

NOTE !

The comparison tolerance value can be changed from inside the compare control panel. The following interface will be displayed :

(39)

The slider bar can be used to modify the transparency of the first and second component. If you switch OFF the ‘show common faces’ option only the faces that have changed will be displayed.

Using the slider bar we can see that on the new part revision, the diameter of the internal diameter has been modified.

Select the ‘Apply’ icon

Selecting the ‘Apply’ icon will retain the colours of the comparison faces. In this case blue faces will be created on the original model and yellow faces will be created on the revision model.

With the comparison faces a different colour from the rest of the model, we can use the

‘Analyse Face Colour’ option to automatically separate the modified faces.

(40)

Window > View > Set Drawing Filters

To make the model selection easier we can use the layers to only show the ‘revision

component’ layer.

It is possible to switch on/off multiple layers using the Windows™ standard CTRL and SHIFT key selection.

Analysis > Analyse Face colour

This option will analyse a model and automatically detect all face colours present on the model. Using the interface available, it is then possible to assign any face colour to any layer.

Select the solid to analyse – Select the revision solid

The following dialogue box will be displayed

Select this model

‘Double click’ the yellow core layer name and the following dialogue box will appear :

Create new layer Make the ‘component revision’

(41)

Select the Create a new layer icon and create a new layer called ‘modified surfaces’

Select the new layer in the dialogue box and select OK

Selecting OK will now create a new set of yellow surfaces on the ‘modified

surfaces’ layer.

Window > View > Set Drawing Filters

With the modified surfaces extracted we can now use the layers to show only the

‘modified surfaces’ and also the ‘core’ layer.

Vcamtech Co., Ltd 6

Select this layer

Destination layer De-select the tick for

the pink surfaces. This will prevent this set of surfaces from being extracted. We are only interested in the yellow modified surfaces.

(42)

Wireframe > Draw Edges

Using this operation we will create the peripheral edges of the modified surfaces as wireframe geometry. We will then use these new curves to cut the core model. It is then possible to remove the faces no longer required on the core model and replace them with the yellow modified surfaces. Ensure that the ‘Select all peripheral edges of a sheet body’ icon is selected

Select the body to create the curves – Select the yellow modified surfaces

Analysis > Split Body

Select the body to split – Select the core model Select the splitting elements – Select All geometry

Accept the splitting tolerance

Select all peripheral edges of a sheet body

Select the yellow modified surfaces

(43)

6 sheet bodies will be created

With the core model now split, it is possible to remove the faces that will be replaced using the yellow modified surfaces

To rebuild the core solid model with the new surfaces it is only a case of uniting all remaining core surfaces (pink) with the modified surfaces (yellow)

Operation > Unite

Select the first target body – Select any pink core surface

Select the tool (sheet) bodies – Select all elements (only surfaces can be selected)

Accept the default knitting tolerance

Congratulations, a new core SOLID model will be generated and the colour of the modified faces will be maintained. This completes the ‘Core Modification’ tutorial.

Vcamtech Co., Ltd 8

Delete these faces (Blue) from the core model.

(44)

VISI-Mould

(45)

VISI Mould - Tool Build Tutorial

Objectives

The object of this exercise is to use the VISI Mould module to create an injection mould tool in 3D as a solid model assembly. The tutorial will introduce the basics of Mould plate configuration, inserting standard components, cooling channels and basic mould

manipulation.

Further exercises in conjunction with this tutorial will show you how to create and insert User Elements, create Plot view detailed drawings and add a parts list table using Assembly Manager.

The tool you will build in this tutorial will be in no way fully complete, but will give you a good understanding of how the Mould functions work.

The inserts used in this example are shown below for illustration purposes:

-¾ Loading the File

Lets begin by opening the file required for this tutorial.

Select the File | Open command and select

start-inserts.wkf.

(46)

¾ Configuring the Mould Base

First we need to select the Mould Tool command and select the two plates: - Select Mould | Mould Tool

A rapid building of plates will now occur and the side docked Tool Assembly dialog box will appear. Note that by default the system uses the Hasco database. We will be using this database for our mould tool design.

The tool has been created only in “Preview Mode” meaning we have not committed to this layout at this point in time.

Pick the fixed half insert to begin the mould configuration.

(47)

¾ Setting the Tool Options

The first thing that we will do is set up the specific parameters that relate to our tool design, such as insert width, gap between plates etc.

¾ Select the options button as shown.

The following dialogue box will appear, set the parameters as shown below.

Once finished setting the parameters, select ‘OK’.

Vcamtech Co., Ltd 3

We require at least

30mm and 10mm

clearance in X and Y from the edge of the insert to the centre of the column.

A suitable plate size is then selected from the Hasco database based on these values. A clearance gap of

5mm and 15mm above

and below the origin is required. A total gap of 20mm is applied between the two Z20 plates.

Select the Options button.

Tool Origin, Allows

you to change the relative position of the tool to the currently selected workplane.

Option, Allows you to

select the current catalog and template to be used.

(48)

Notice how the system automatically picks the most suitable plate size in the range (246_346) and the gap between the cavity and core plate is created in preview mode.

¾ Configuring the plate layout

Now that we have the correct mould base key size, the next task is to configure the mould plates to the correct size and type.

¾ Delete the Insulation Plate from the configuration, Injection side.

Plate key size based on the clearance values 10mm and

30mm.

20mm gap now applied between core and cavity plates.

Select the Z121BLSD from the tree and click with the Right Mouse

Button to see the pop up

options.

Pick the option Delete

Plate from the list.

Click Yes to confirm removal of the plate.

Insulation Plate will be removed

(49)

¾ Delete the Insulation Plate from the configuration, Ejection side.

Now that we have the desired plate layout it is time to set the thickness for the plates on both Injection and Ejection sides of the tool.

¾ Set the plate sizes for the Injection side of the tool

Select the ‘K20’ plate in the treeview

The bottom window updates to show the following. We will now change the Z dimension to update the plate thickness.

Vcamtech Co., Ltd 5

Select the Z121BLSD from the tree and click with the Right Mouse

Button to see the pop up

options.

Pick the option Delete

Plate from the list.

Click Yes to confirm removal of the plate.

Click Here Double Click Here In the Z Dimension box 246

(50)

The z dimension combo box opens to reveal the available plate thicknesses for this plate from Hasco. Select ‘56’ from the drop down

You will notice the preview of the Cavity plate updates on the screen. Any values for any of the plates can be changed in the tree to update the tool on the fly.

¾ Changing K10 Plate thickness

We will now select a different plate thickness for K10. Click the box containing ‘36’ for Z dimension. The list of available thicknesses for the plates in the catalogue is displayed. Select ‘27’.

You will now notice the Top plate thickness updates automatically.

Choose 56 from the drop down

Select the K10 plate.

Click in the Z dimension drop down and select 27

(51)

¾ Adjust the Ejection side plate dimensions

In a similar way to the previous example let’s adjust the plate thickness for all the remaining plates to suit our design intent.

For the injection side here are the required dimensions: -

If you have not followed the previous steps please adjust these now.

Now configure the Ejection side: -

Now adjust the plate sizes to those shown below for the ejection side. If you are unsure take a look through the previous steps to refresh your memory.

Vcamtech Co., Ltd 7

Select the Ejection side node from the tool tree.

Now adjust each individual plate

Z depth to the values shown

below by clicking in the Z dimension box. K20 K40 K11 K60 K70

(52)

¾ Apply the Changes made.

We have now completed editing the plates. Before we can move on to the automatic creation of standard elements we must accept the plate configuration so that they are no longer just in preview mode but added to the CAD database.

¾ Automatic Configuration Of Standard Elements

Now that we have defined our plate layout it is possible to insert the “Base” standard elements that belong to our bolster kit. This is done in a semi automatic fashion and will be demonstrated in this section of the tutorial.

¾ Switch to Standard Element Mode

Click the Apply button to add the plate layout to the database.

At the top of the Tool Tree interface, click the standard

elements tab.

The Standard Elements window will now appear as shown opposite.

The next task is to configure the Standard Elements to suit our tool design. See overleaf.

(53)

Location Ring

In this example we will be inserting a custom location ring and not one from the standard library. With this in mind it will be required to disable the location ring from its respective dialogue window as shown below. Please note there are 2 location rings that need to be disabled.

Screws

Now configure the Z31 cap head screws for the Top Clamping Plate and Riser.

Guide Pillars

For this tool we will be using a Hasco standard shouldered pillar Z00, configured as shown below. Set your tool parameters to match.

Vcamtech Co., Ltd 9

Uncheck the “Insert Element” checkbox to ensure that the location ring will not be included in the tool assembly.

(54)

Bushing For Guide Pillars

For the guide bush we will use the Hasco Z10 Guide Bush with Spigot, configured as shown below

Guide Bush / Tube Dowels

For the guide bush / tube dowels we will use the Hasco Z20 tube dowel configured as shown below. Make sure that the Alignment is set to a bottom position.

Stop Buttons

In this particular tool we will not be using Stop Buttons.

This checkbox will align the tube dowel to the bottom of the K11 plate

Remove the “Tick” from the checkbox so that this component is not inserted.

(55)

Cap Head screws

For fixing together the ejector plates we will use a Hasco Z31 screw as configured below.

Return Pins / Push Backs

For the return pins we will be using Hasco Z41 type, this requires you to pick from the drop down list as shown below.

When you have chosen the Z41 from the drop down list select the diameter 12. Shown below is the final configuration for the Z41 return pins.

Cap Head Screw – Not Required

The final cap head screw in the list is not required for this design. This is an optional screw only required is 2 sets of ejector plates are being used in the design.

Select the Drop Down arrow to pick from the available list. Select Z41 from the list.

(56)

Countersunk Ejector Pin – Not Required

The countersunk ejector pin in the list is not required for this design. This is an optional item only required if 2 sets of ejector plates are being used in the design.

¾ Preview the Standard Elements

It is now possible to preview our Standard Elements configuration by using the preview facility.

Note :- Now that we have previewed the components, it is possible to adjust some of the

sizes that were not available before the preview had taken place.

Click on the “Preview All Elements” icon to show the components within the mould.

(57)

¾ Adjust Guide Pillar Lengths, Guiding length 75, Shoulder Length 56.

It is not necessary to change any of the other Standard Element default sizes, as they will be suitable for this tool design.

¾ Confirm the Standard Element configuration.

To store the changes made to the Standard Element layout and take them out of preview mode we need to confirm the changes using the Apply button.

¾ Opening the Tool

As a final operation we can open the tool by rotating around a specific axis. For this task we will need to switch back to the “Tool” interface.

The first thing we need to do is to set our Cavity Insert to the Injection Side so that it will open onto the correct side.

Setting the Injection side

Adjust the Guiding Length and Shouldered as shown opposite.

Click the Apply button to store the Standard Element configuration.

Click the “Injection” node in the tool tree and then Right

Mouse Button to reveal the

pop up options.

Click the “Set Injection side” option from the pop up.

(58)

Now we can open the tool knowing that our Cavity Insert will on the correct side of the tool when it is rotated round the selected axis.

Open the Tool around the X axis

The options here allow us to open the tool about certain axes separated by a gap defined by the user

Select the ‘Open X axis’ option and use a gap value of 200. The tool updates to the following view

Tool shown in Open position around X

Right Mouse

Click on the root of the tool tree.

Select Open X Axis

Now select the Cavity insert from the screen to set this on the injection side.

(59)

To close the view ‘RHM’ click the parent node again and choose the ‘close tool’ option.

Tool shown back in the default closed position.

You have now successfully completed the Tool Build tutorial. The next section will cover insertion of Standard Elements into the mould tool.

Right Mouse Click again at the root of the tool tree.

(60)

VISI-Mould

(61)

Objectives

Now that we have created the mould bolster configuration and the default standard elements, it is time to start inserting Standard Element components from the supplier catalogues.

For this task we will begin from the last completed stage of the training and it is required to load the starter file as detailed below. Do not worry if you have not managed to complete the previous training exercises as the starter file will bring you right up to the correct point for this section.

¾ Loading the File

Lets begin by opening the file required for this tutorial.

Select the File | Open command and select plates&stdelem.wkf

(62)

¾ Creating the Pockets For The Inserts

Before we add any more components to the mould we need to create pockets in both the K20 plates, to house the inserts. To do this, follow the next sequence: -

Use the layer manager to display the layer list and activate only the layers shown below.

Firstly, lets cavity the pocket-solid away from the CAV plate, by doing this we will retain a copy of the pocket solid, but create the pocket hollow in CAV.

Select the Cavity function from the pullout tool bar or Operation > Cavity

CORE CAV

POCKET-SOLID

NOTE: - Pocket solid is a pre-made solid

that is saved with the tutorial eliminating the need to create a solid at this stage.

1.Select Target Body(CAV) 2.Select Cavity Body Leave Offset for cavity at ‘0’ and select OK

(63)

Now we need to Subtract the pocket solid from plate CORE. This operation will delete the pocket solid and leave the resultant pocket in CORE.

Select the Subtract function from the pullout tool bar or Operation > Subtract

Vcamtech Co., Ltd 3

1.Select Target Body 2.Select Tool Body

The Result - Sectioned view for illustration

purposes shows both pockets for the inserts.

Now turn on all the layers with the SET/RESET icon in the layer manager as shown below.

(64)

¾ Screwing the Inserts to the K20 plates

Our next task is to screw the Fixed Half Insert and the Moving Half Insert into their respective K20 bolster plates

Set the Layer list to display only the 4 layers shown

Follow the next sequence to add the screws: -

You will now be presented with the lower docked dialog screen for catalogue / component choice.

Now select the “Fixing” tab to display the list of fixing components, as shown below.

Select Standard Element from the Mould drop down

Pick on the “Suppliers” icon and select “Hasco” from the available pop-up list.

(65)

Select the Z30 screw from the Fixing menu.

Now select the Start Plate and End Plate as shown below

Vcamtech Co., Ltd 5

1.Select Start Plate K20 fixed half. 2.Select End Plate Fixed Half Insert

You will now be presented with the ‘Element Data’ dialogue box. This is the area where the parameters can be set for each component in the library.

It will appear in active until you pick a start and end plate for component insertion.

You must select a Start Plate and End Plate as shown below.

(66)

Next select the Application Point

Note: - It is possible that you may not see a preview

of the screw because it has been inserted on the

Standard layer which is not currently visible.In the

next step we will fix this situation.

Now adjust the parameters for the Z30 element as shown below.

Once you have set the parameters click the Add Instance button to insert the element into the model (it is no longer a preview).

3. Application Point can be any one of the Fixed

Half insert’s corner rads.

Use the centre snap icon to snap to the radius corner.

Change the Layer drop down menu to ‘CAV, to apply the components to this layer.

Preview of Screw

Change the ‘Diameter’ parameter to 6mm

Select the Add Instance button.

(67)

You now have a chance to insert extra instances of the same component because the

Apply checkbox is flagged in the Element Data window.

Please press the ESC key to cancel the insertion of extra instances as we will insert these in a different way.

Now insert 3 more screws to the remaining corner positions.

This can be done using the main Edit menu in the CAD or from the Edit Elements area.

Vcamtech Co., Ltd 7

The Apply button is checked, meaning extra instances can be inserted after the first instance is added.

Pick the Mirror option from the Edit drop down menu.

Select the Z30 screw.

Screw is Mirrored to the 3 new positions to secure the insert.

From the Left Hand side Menu select the ‘2 Direction’ icon to mirror the screws to the other 3 corner positions.

Pick the No option because the start / end plate thickness are the same.

Rebuild: - Because we are

transforming the standard elements to different positions the system will ask if we need to rebuild the Elements to suit the new locations.

Select the co-ordinate position that represents the tool centre.

(68)

(69)

Now your turn – Quick Exercise – Insert Core Screws

Z30 screws into the moving half. Use the

arameters and positions indicated.

e the Edit function for the screw copies.

Now that you have performed this task on the Fixed Half Insert use the same method as shown in the previous example and insert 4 x

p

R member to use

Make sure the CORE layer is the current layer before starting this process. All the screw cavities will be placed on this layer.

Check Layer

¾

Result. Insert at positions shown (Centre of Rads.)

From the Left Hand side Menu select the ‘2 Direction’ icon to mirror the screws to the other 3 corner positions.

(70)

Inserting a Sprue Bush (Hasco Z511)

rt a Hasco Z511 Sprue bush into the mould assembly, please follow the ext set of instructions to perform this task: -

ow pick the start and end plates to insert the Sprue Bushing. The start plate will be the 20 plate and the end plate will be the Fixed Half Insert as shown below.

We will now inse n

Activate the layers should display below.

shown in the layer manager. This resemble the

N K

Pick the Z511R ponent from the Sprue

Bushing tab menu of the HASCO library.

com Select Standard Element from the Mould drop down

1.Start Plate

K20

2. End Plate

FH insert. Make sure CAV is current layer.

(71)

Now insert the co-ordinate position. The injection point for this tool is right on the centre 0,0 origin point.

3.The application point

should be set to absolute 0,0,0.

Use the parameters shown opposite, making sure the CAV layer is selected.

Insert the parameters as shown opposite making sure the Guiding length is set to 18.

Select the Add Instance icon to insert the sprue bush into the database.

Sprue bush shown in position.

(72)

7.0 Adding a Custom Register Ring – User Element

g has been pre-modelled and is not part of the Standard Elements atalogue. It has been custom modelled to suit the tool design and will be inserted as a

ser Element. Follow the next sequence to insert this component.

ould > User Elements > Load User Element

oup should be: -

Full Training Course\2.standard-elements\user

he user element will now appear attached to the cursor and can be dragged around the creen to position.

r the user element using the snap icons on left side of the The register rin

c U M T C T s N s

he path for the “Register Ring” gr

:\V15 Training Material\Mould\

ow choose the insertion point fo creen.

Pick the Centre of the Sprue Bush for location

Select the centre snap icon.

Pick this edge on the top face of the sprue to locate the centre.

(73)

The Result – Shows the Register

Ring in position.

The register ring is part of a “solid group” and therefore cannot interact with any standard omponents. To make the group behave like a regular solid we need to dissolve the r

odelling > Solid Groups

he solid group ed and therefore the solids group manager should be

hould be empty.

is now possible to use standard elements with the Register Ring solid. c

oup

.

g

M

From the solids group manager, select the “register ring” group and click the Right

Mouse Button.

Select the “Dissolve solid group” opt from the pop out menu.

ion

Select “Yes” from the following dialogue box to proceed with the dissolve process.

T will now be dissolv

s

Close down the empty solid groups manager by clicking the cross as shown.

It

(74)

Quick Exercise – Screw In the Register Ring

be is your task; remember to Now we have located the Register Ring onto the top plate of the Mould Tool, it needs to fixed into position with 2 x M5 Socket Head Cap Screws. This

refer to the previous exercises if you are unsure of how to do this.

Use a Z30 screw from the tab menu of the

HASCO library.

Pick the Register Ring as the start plate.

Pick the K11 Top Plate as the Endplate.

Application Points (Absolute)

X0, Y40, Z0

X0, Y-40, Z0

The Result – Side View

Check Layer is set to TOP

Here are the Z30 screw parameters. For this task we are using a 5 x 16 screw and due to the depth of the screw and the plate thickness we will create the screw with a through hole

Screw Parameters

Change the diameter to 5 and body length to 16.

(75)

Inserting Ejector Pins (Hasco Z41 )

At this stage of the design we will be inserting several different size ejector pins into the ol assembly. The following examples will show you how: -

o make the task of inserting the ejector pins into the assembly easier we will again filter e layers selecting only the ones relevant for the task.

ow call up the olbar from the Mould menu.

to T th

A ate only the 3 layers shown opposite. Make sure that UPP is the current layer.

ctiv

N standard element to

The display should like the one shown

Select Standard Element from the Mould drop down

Select the Ejector Pins tab and choose the Z41 pin from the menu as shown.

(76)

¾ Pick the Start Plate and End plate for the Ejector Pin and then the application point.

End Plate MH-SUB1

Start Plate EJE5

Use the application co-ordinate shown above

Now insert the Ejector Pin parameters as shown ¾

Change the destination layer to UPP.

Select an Ejector Diameter of 4mm.

Ejector Pin Parameters. Make sure the Guiding

Length parameter is 29.

(77)

Now make 3 extra copies of the Ejector Pin using a symmetrical mirror. To perform this indow.

¾

task we can use the functionality in the ‘Edit Elements’ manager w

Pick the Edit Elements option from the Mould drop down menu.

Select the Z41 ejector pin from the element list.

You can now see one inst lower split pane window. Click

Button to reveal the pop up menu.

ance of the Z41 ejector in the the Right Mouse

The Result. The ejector pins have been

copied to the other 3 positions, around the datum.

We do not need to rebuild standard elements as the start and end plate thickness will be the same for the transformed components.

From the pop up menu choose the ‘Mirror Instances

around a Point’ option.

Use the Insert co-ordinates icon.

The application point should be set to absolute 0,0,0.

(78)

Now your turn – Quick Exercise – Insert 2 Ejector Pins

ow that you have performed this task with the 4mm Diameter Ejector Pins use the same ethod as shown in the previous example and insert 2 more ejector pins. Use the

arameters and positions indicated below. Note: - Start and End Plates for these

omponents are the same as the previous example

Inserting Sprue Eje N m p c ctor 1 ¾

Parameters Application Point

Make sure the UPP layer is selected. Se m Ejector diameter. lect a 6m Use a 15mm guiding length.

(79)

¾ Inserting Sub Gate Ejector 2

Note: - Start and End Plates for these components are the same as the previous example

Congratulations, if you have inserted all the ejector pins correctly you should have a result similar to the one shown above. In the next section we will be inserting Lifters.

Parameters Application Point

Ejector Pin shown in position.

Select a 8mm Ejector diameter.

Make sure the UPP layer is selected.

Use a 15mm guiding length.

(80)

VISI-Mould

(81)

VISI Mould - Inserting Lifters

Objectives

Having now inserted some basic standard components we will move onto the automatic creation of Lifters. The lifters are required to help mould the undercut features on the product such as clips and slots that may be difficult to form with any other method.

For this task we will begin from the last completed stage of the training and it is required to load the starter file as detailed below. Do not worry if you have not managed to complete the previous training exercises as the starter file will bring you right up to the correct point for this section.

¾ Loading the File

Lets begin by opening the file required for this tutorial. Select the File | Open command and select lifter-start.wkf