Mold Design using SolidWorks

Mold Design using SolidWorks

  • Pre-requisites : For Mechanical & Automotive Engineers
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A Quick Overview

If you had the privilege of being in a FIAT Padmini, you would have noticed how the metallic interior and exterior stood out. It was built like a tank because of which the car was heavy. If you notice the cars running on the streets today, the interior and exterior have significantly more plastic components. Even if you take a look at many of the appliances that you use today, you would notice the rise in the number of plastic components. 

In India, the rate of growth of the plastics industry is almost 16% per annum as per a report by British Plastics Foundation. The reports show that there is not going to be a drop in the rate anytime soon. With this, you can pretty much understand the importance of the plastics industry and the time and effort that goes into making a plastic component.

We, at Skill-Lync, have come up with a course that will help you understand what you need to know to enter into this industry. This course is tailored in such a way that anybody with a basic grasp of any modelling software will be able to finish this course. 

The course contains 12 weeks of curated content taking you through the very basics of SOLIDWORKS where we help you master all the commands required for you to start working on the tool. Following which you will be introduced to the basics of plastics and injection moulding where you will get a better understanding of the processes involved. We then take you through the steps involved in creating a basic mould for simple parts. Over the following weeks, you will be introduced to more complex concepts in mold design. 
Through the duration of this course, you will be required to work on challenges that pertain to each week of content so that you get to work on the models that you see in the explanation videos as well as extra models that will challenge you to think ahead and use the concepts learned in the videos


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COURSE SYLLABUS

1Basics of Injection Molding / SOLIDWORKS Modelling

This section will cover the following basic concepts

  • Injection molding process and how it works
  • Plastic processing methods such as 
  • Rotational molding
  • Extrusion
  • Vacuum forming
  • Blow molding
  • Gas-assisted injection molding
  • Mold cycle and the factors affecting it
  • Thermoplastics and thermosets
  • The current trends in the industry
  • The types of plastics being used
  • The properties of these plastics and, 
  • How to select them

For the uninitiated, we’ve also included a session on the basics of SOLIDWORKS where we take you through

 

  • Basics of sketching
  • Basics of using features in SOLIDWORKS

2Basics of Mold Design / SOLIDWORKS Surfacing

After getting a basic understanding of injection molding from the previous session, in this session we will jump into the technical side of designing the mold.

 

The topics we will be covering are:

  • How the product development process takes place in the plastic industry
  • Various departments in plastic manufacturing industries and the workflow
  • Parts of mold - core, cavity, guide pillar, sprue, register ring, guide bush, ejector pin,  return pin, spacer blocks, core plate, cavity plate, ejector plates, etc.
  • 2 plate & 3 plate molds
  • Drafts
  • Parting lines

 

In the SOLIDWORKS session, we will continue where we left in the previous session and learn about the various surface tools used for designing.

3DFM and Defects

In the third week, we will be covering theory related to various concepts and terms used in mold design. The topics we shall cover are:

 

  • Concept of machine tonnage and how to calculate it
  • DFM study where we will look at various concepts such as gate point, wall thickness, cores, tolerance, venting, ejector pads, inserts, ejector inserts, guide pillar, support block, relief, free play inserts,  multi-gate position, and flow leader.
  • Various defects that may occur during the mold design process such as short shot, flash, weld lines, sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking, and unbalanced flow.

4Parting Surface / Mold Design Tutorial 1

In the fourth week, we will be studying the theory behind parting surfaces. The topics that will be covered are as follows:

 

  • What is a parting surface?
  • Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
  • Example cases where we will try to understand the selection of parting surfaces
  • Matching drafts
  • Shrinkage 
  • Inserts 

In the SOLIDWORKS session, we will start with our first mold design tutorial. We will be covering a simple plastic component and we will learn the following:

 

 

  • Doing draft analysis for the model
  • Creating parting lines
  • Creating shut-off surfaces
  • Creating parting surfaces
  • Create basic mold blocks

5Sliders and Ejection System/ Mold Design Tutorial 2

In the fifth theory session, we will be looking at the topic of sliders and ejection systems. The topics that will be covered are:

  • Need for sliders and their working. 
  • 2 general types of sliders - sliding split type molds and the angular lift pin type molds.
  • Methods of actuating the sliders such as finger cam, dog leg, cam track, spring and the hydraulic actuation
  • Concept of slider locking
  • Various types of ejector systems such as pin, sleeve, stripper and blade ejector systems.

In the SOLIDWORKS session, we will be creating a mold for the outer cover of a disposable camera.  The steps we will follow are mentioned below:

 

  • Creating parting lines, shut-off surface, parting surface, and mold blocks for the model.
  • Creating ejector pins for the mold.
  • Creating inserts for the mold.

6Gates and Runners / Mold Design Tutorial 3 - Part 1

In the sixth week theory session we will be learning about runners and gates. The various topics covered are as follows:

  • Types of gates such as sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarine and cashew gates.
  • Runner diameter calculation
  • Types of runners
  • Runner configurations
  • Why engravings are used in cavity



Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. The topics that will be covered are as follows:

 

  • Creating the parting lines, shut-off surfaces and parting surfaces of 3D profile for the model.
  • How to work in assemblies and how to arrange files in a specific format.
  • How to align the sprue of the mold with the origin of the assembly.
  • How to select proper dimensions for the mold blocks.
  • Creating mold blocks for door bezel.

7Mold Design Tutorial 3 - Part 2

In the seventh week, we will continue working on the door bezel model from the previous session and learn the following topics:

 

  • Locating undercuts in the model and understanding how the use of sliders will help in solving the undercut issue.
  • Creating slider split
  • How to assign proper dimensions to the slider
  • Editing the core cavity blocks according to the shape of the slider.
  • Creating bolts, washers and locking mechanism for the sliders.

8Mold Design Tutorial 4 - Part 1

In the eighth week, we will start creating a mold for a CPU fan case model and we will learn the following topics:

 

  • Complex parting line selection that can reduce the number of sliders required for the model.
  • How to provide correct matching drafts for the model.
  • Then we will create the core-cavity surfaces for the model. After that, we will align the sprue location, select dimensions and create the mold blocks for the CPU fan case in assembly. We will also see how to add reliefs for the core-cavity blocks.

9Mold Design Tutorial 4 - Part 2

In the ninth week, we will continue working on the CPU fan case model and we will learn the following topics:

 

  • Locating undercuts in the model 
  • Creating a slider split for the undercuts.
  • Assigning proper dimensions for the sliders.
  • Providing reliefs for the sliders.
  • Creating inserts for the model.

10Mold Design Tutorial 5 - Part 1

In the tenth week, we will start creating a mold for a plastic knob model and we will learn the following topics:

  • Creating the parting line, shut-off surface and the parting surfaces for the plastic knob model model. 
  • Automatic and manual shut-off surface creation.
  • Core-cavity surfaces for the plastic knob model.
  • Sprue alignment
  • Selecting dimensions and creating the mold blocks for the plastic knob in assembly. 

 

We will also be covering some theory behind the cooling channels for a mold.

11Mold Design tutorial 5 - Part 2

In the eleventh week, we will continue working on the plastic knob model and we will learn the following topics:  

 

  • Creating multiple inserts for the model
  • Creating holes for fixing the inserts. 
  • Locating undercuts and creating a slider split for it
  • Complex slider creation
  • Assigning proper dimensions for the slider.

12Mold Design Tutorial 5 - Part 3

In the twelfth week, we will continue working on the plastic knob model and we will learn the following topics:  

 

 

  • Creating an ejector system which will include the angled ejector pins, reliefs, ejector plates and ejector back plates.
  • How to make the channels for plastic injection which will include the sprue, runner and gate for the mold.
  • Understanding the use for providing air vents in a mold and then creating channels for the passage of air from the mold.
  • How to select the dimensions and positions of the cooling channels in the mold and how to create them


Projects Overview

Project 1

Highlights

For your first project on mold design, you will be working on creating a proper mold for a table fan stand. Though the table fan stand may appear to be a fairly common and simple product to manufacture, due to the presence of undercuts (explained in the course) in the model, it is actually not possible to manufacture the product using just two standard core-cavity mold blocks. In order to deal with external undercuts along with the creation of proper core-cavity mold blocks, the creation of proper additional sliders is also necessary. The process of the creation of sliders will be covered in the course for other models. The students will be expected to understand the concept of sliders applied to other models covered in the course, and then apply those concepts learned to the table fan stand model. Thus, working on this project would prove to be both challenging as well as provide insight and experience on how to use sliders while creating a mold for a component.

 

 

Project 2

Highlights

For the second project, you will be creating a mold for a fan bezel. A fan bezel is the outer structural support on which the fan is mounted. The material for this component varies based on the application. For larger industrial fans, you will find metals being used, whereas when made for smaller CPU cooling fans, the use of plastics will be preferred.

 

The complexity of this project lies in both the creation of core-cavity mold blocks as well as the sliders. Since, by the time you start working on your second project, you will have some experience in creating molds for multiple plastic components, we have specifically selected a model for which the creation of mold blocks won't be straightforward. You will have to carefully select the parts that should be in the core block and the parts that should be in the cavity block. Also, creating a proper mold for this model will require the use of multiple sliders, and you will have to carefully decide on the number and position of the sliders that you plan to use such that the manufacturing costs are kept minimum.

 

Along with the core-cavity blocks and the sliders, you will also be creating multiple other components such as the ejection system, runners and gates, air vents, and cooling channels for the fan bezel model.

 


WHO IS THIS COURSE FOR ?


  • Students in Mechanical or Automotive engineering
  • Freshers looking to gain project experience on Mold Design
  • Professionals who want to build upon their existing SolidWorks skill sets and move forward to greater roles in the company

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  • Access Duration : 2 months
  • Mode of Delivery : Online
  • Project Portfolio : Available
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  • Access Duration : Lifetime
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Frequently Asked Questions

1Who can take your course?

Engineers who are currently working in the industry and looking for a skill-up in their domain, and students who have written the FEA paper in semester 6.

2What is included in your course?

Meshing of interior trims(plastic),Chassis components(suspension system,and controlling links).

3What will the student gain from your course?

    i) Basics of FEA

   ii) Meshing of components or assemblies by using 2D,3D and 1D elements.

   iii) Decision-making ability towards fixing of element size, element types, creating geometric and material properties.

  iv) Assembly connection which resembles the physical scenario.

  v) Automatic mesh( batch mesher) and scripting to develop macros

4What Software skills are you teaching and how well are these tools used in the industry?

SOLIDWORKS is the software that is taught in this course.  This two software widely used in Mechanical, Electrical & Civil structure Companies who does CAE analysis to reduce design cost and time.

5What is the real world application for the tools and techniques taught in this course?

With the help of SOLIDWORKS we can mesh and assemble entire vehicle and perform CAE analysis like Structural, Dynamic, and Thermal Analysis.  

6Which companies use the techniques and tools that are taught in this course?

Automotive industries,Aerospace industries, ONGC industries, Power Production industries.

7How is this course going to help me in my path to MS or PhD?

 SOLIDWORKS helps to ensure better research studies to find new materials, better optimized structural design in the areas of mechanical, electrical, civil structural and thermal domains.

8How is this course going to help me get a job?

This coursework transfers a more industry-related experience to approach day-to-day design issues and process.  It will help to get the job in the mechanical design field.

9How much time should I spend each day to complete the course?

A dedicated 2 hours of time is more than enough to understand the concepts, noting the concepts down and performing the challenges.


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