Functional Molded Parts
CATIA V5 Training Foils
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Functional Molded Parts
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Version 5 Release 19 September 2008 EDU_CAT_EN_FMP_FF_V5R19
Student Notes:
Functional Molded Parts
About this course
Student Notes:
Objectives of the course Upon Completion of this course you will be able to: - Define the main shapes of a molded part in terms of material added or removed from the mold of the part. - Add functional features such as, ribs or cutouts to the part. - Finalize the molded part using the feature modifiers such as fillets or patterns. - Use the multi-body approach. - Extract cores, cavities and other EDM inserts from the final part.
Targeted audience Molded Part Designers
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Prerequisites Students attending this course should have the knowledge of CATIA V5 Fundamentals
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1 Day
Functional Molded Parts Student Notes:
Table of Contents (1/3) Basics of functional Molded Parts Introduction to Functional Molded Parts Mold Design Properties Summary
Basic Features Introduction to Basic Features Behavior of Basic Features Shellable Feature Other Basic Features To Sum Up
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Functional Features
6 7 21 27
28 29 30 33 43 59
61
Basic Behavior of Functional Features Rib Feature Example Rib Feature Other Functional Features To Sum Up
62 63 64 66 76
Feature Modifiers and Dress-Up Tools
77
Introduction to Feature Modifier
78
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Functional Molded Parts Student Notes:
Table of Contents (2/3) Feature Modifiers in Brief Remove Feature Other Feature Modifiers To Sum Up
Multi-Body Features Multi-body Approach with FMP Divide Feature Lip Feature Flange Feature Join Feature Snap Lock Feature To Sum Up
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Extraction Features Extraction General Process Core Extraction Cavity Extraction Cavity/Core extraction – Methodology tips Extraction Properties
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80 82 87 94
95 96 97 99 101 103 104 107
109 110 111 112 113 114
Functional Molded Parts Student Notes:
Table of Contents (3/3)
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Volumes Extraction Behavior Extraction Feature To Sum Up
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116 118 119
Functional Molded Parts
Basics of functional Molded Parts This lesson will introduce you to the Functional Molded Parts workbench. In this lesson, you will also learn to assign 'Mold Design Properties‘ to the part.
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Introduction to Functional Molded Parts Mold Design Properties Summary
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Student Notes:
Functional Molded Parts
Introduction to Functional Molded Parts
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This skillet will introduce you to the concept of Functional Molding, and will take you through the Functional Molded Part workbench.
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Student Notes:
Functional Molded Parts Student Notes:
What is a Molded Part? A part manufactured by a molding process is called “Molded Part” A ‘Molded Part’ should respect specific design rules to satisfy manufacturing process constraints like: “It should have constant wall thickness in most of the cases”, “It should be releasable from the mold”, etc.
CAVITY = outer shape
MOLDED PART
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MOLD
CORE = inner shape
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Functional Molded Parts
Function Versus a Feature Feature is a tool to create/modify shapes. Function is shape of a body (Part), incorporating a behavior to cater specific requirements. Therefore, a Function can be perceived as a Feature + a Behavior A Functional feature is the ‘Functional Molding’ tool, which enables you to design parts keeping in mind both ‘Feature + a ‘Behavior’.
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In the above example, the circled region shows pockets which are created for the phone receiver.
Protected Feature In FMP, these pockets will be created by a ‘Protected Feature’ which prevents material addition into its volume.
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Student Notes:
Functional Molded Parts Student Notes:
Why New Functional Features? The FMP workbench helps the designer to design the parts that can be perfectly manufactured. Designing the part using FMP workbench has the following advantages: Decrease in number of Features for each shape to be designed. Increase in the robustness in case of design change. Increase in the possibility of making a design right the first time (from manufacturing point of view).
FMP helps the designer to design Shapes that are suitable for manufacturing.
Functional view
Manufacturing view MOLDED PART
Guiding hole
CAVITY = outer shape Locating
Housing
MOLD
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MOLDED PART CORE = inner shape
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Contact
Functional Molded Parts
Designing with Functional Molded Part (1/4) New philosophy of designing with FMP The solid of the part is a made up of Functional Features, which are order independent (not imposed sequence in the design). Consequently the resulting geometry is always the same, irrespective of the position of features in the specification tree. The resulting solid is fully compatible with any CATIA workbench. You can reuse Part Design Bodies to directly modify the part for detailed design. Legacy catalogs can also be re-used. For understanding the design intent / process, you can re-order the features in the specification tree.
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The designer can begin the design by defining the specifications before the main shape: the features’ order does not matter!
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=
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Student Notes:
Functional Molded Parts
Designing with Functional Molded Part (2/4) New philosophy of designing with FMP In FMP, the designer considers the shapes of the part in accordance with the manufacturing processes that will constitute the shape. This philosophy assures that the part is manufactured right the first time. The shorter specification tree makes it easy to carry out design changes. Each feature prompts the designer to consider the manufacturing constraints like: Wall thicknesses Parting elements Pulling directions Drafts Fillets Etc.
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FMP (reduced number of specifications)
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Part Design
Student Notes:
Functional Molded Parts Student Notes:
Designing with Functional Molded Part (3/4) A part designed using FMP workbench can have the advantages of ‘Functional Extraction’ – a tool which can directly extract core, cavity and other inserts of a part.
Cavity volume
Core volume
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From the part
Functional extraction is not only used for mold extraction, but also can be used for analysis of the part, relational design methodology, etc.
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Feature volumes with new behavior (ribs, tools, etc.)
Functional Molded Parts
Designing with Functional Molded Part (4/4) Specification tree characteristics of FMP: “Solid Functional Set" contains the features created using FMP workbench. This ‘Solid Functional Set’ is included in a ‘Non Hybrid Body’
Solid Functional Set contains the list of functional specification. The behavior of these specifications form the resulting solid.
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For each new Solid Functional Set, one ‘Body’ is associated.
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Student Notes:
Functional Molded Parts Student Notes:
Accessing the Workbench You can access the workbench using the ‘Start’ menu as shown.
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Click "Start / Mechanical Design / Functional Molded Part"
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Functional Molded Parts Student Notes:
User Interface and Toolbars (1/5)
1
3
Basic Features: Used to create generic shapes.
Functional Features: Used to create specific shapes.
4
Dress-Up & Modifiers: Used to modify and dress-up the shapes.
7
5
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Multi-body Feature: Used to divide one body in two functional bodies and to provide different solutions to join the two resulting bodies.
Functional Extraction: Used for Core, Cavity and Inserts’ extraction.
2
Mold Design Properties: Used to define shell and draft properties of the current body.
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Functional Molded Parts Student Notes:
User Interface and Toolbars (2/5)
Icon
Name
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Shellable feature
Definition
A Shellable feature is used to define the overall external shape of the part.
External Feature
Adds material. The material will be added only outside a shelled volume, if present.
Added feature
Adds material in any case, except where a volume is protected.
Protected feature
Creates an area, within the body, where additional material cannot penetrate. This is useful if you need to reserve space.
Internal feature
Adds material only inside a shelled volume.
Core feature
Removes material from the thickness of the shelled part, thus increasing its core.
Shell properties
Assigns a wall thickness to an active body and allows the removal of faces.
Draft Properties
Defines draft properties to be applied to the functional features of a Solid Functional Set.
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Functional Molded Parts
User Interface and Toolbars (3/5)
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Icon
Name
Definition
Cut feature
Trims the shapes or a set of selected features of the active body by using surfaces or planes, while maintaining its shell properties (wall thickness).
Remove feature
Modifies one or more features by removing a shape from it.
Intersect feature
Computes the intersection of the shape you define with the features you wish to modify (complementary of remove).
Pattern
Duplicates a set of selected functional features.
Edge Fillet
Computes a fillet on one or more edges of a functional feature. If the volume is shelled, the fillet is propagated into the shell.
Divide
Divides a functional body into two bodies, according to a parting element (both side option).
Lip
Generates a lip on divided bodies.
Flange
The Flange command allows you to add material around divided bodies at the mating face.
Snap Lock
Allows you to create a cantilever type of snap-fit attachments between two bodies. It creates both cantilever and retention mechanism.
Hole
Creates a hole positioned by a point and defines its volume as protected.
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Student Notes:
Functional Molded Parts
User Interface and Toolbars (4/5)
Icon
Name
Cutout feature
Removes material from the active body, based on a selected profile.
Pocket feature
Pockets are based on simple profiles and usually have side walls and a bottom.
Boss feature
Adds material only to the outside of a material volume with which it intersects within the same body.
Rib feature
Adds strength to a shelled body and is typically applied to the inner part of a shelled body.
Rest feature
Removes material from the active body to create a platform-like area.
Reinforcement feature
Creates a set of patterned cuts and holes in the thickness of the part. Mainly used to define air extraction feature. Adds external strength by adding material to the outside of material volumes with which it intersects within the same body.
Push feature
Enables you to use bodies as tools to deform the shell by pushing into it.
Pull feature
Enables you to use bodies as tools to deform the shell by pulling into it.
Fitting feature
Enables you to use a new or existing Body to fit into another body.
Grill feature
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Definition
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Student Notes:
Functional Molded Parts Student Notes:
User Interface and Toolbars (5/5)
Name
Definition
Extraction properties
Enables assignment of protected features to the Core or Cavity extraction feature.
Core extraction
Extracts the Core volume from a Functional solid, associatively in a new Body.
Cavity extraction
Extracts, the Cavity in the form of a Protected Volume, associatively in a new Body from a Functional solid.
Volume extraction
Allows you to extract the volumes created by a body or feature into another body.
Behavior extraction
Duplicates associatively a function allowing to change its current behavior.
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Icon
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Functional Molded Parts
Mold Design Properties
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You will learn about the design properties of the part and the ways and methods to control them.
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Student Notes:
Functional Molded Parts Student Notes:
Shell Properties (1/2) The ‘Shell Properties’ define the basic properties of the current ‘Solid Functional Set’. These properties include – Overall thickness of the part, faces to be removed etc. The first time you create ‘Wall Based Feature’ like ‘Shellable’, ‘Cut’, ‘Boss’ etc, the ‘Shell Properties’ feature automatically gets created. You have to edit the shell properties and select at least one face for the opening. The core volume is limited up to the removed face. 1
Double-click on “Shell properties”.
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2
Select the faces to remove and enter the thickness value.
• The default Thickness = 0mm means solid which is not hollowed. • Advanced tab allows to apply specific wall thickness on other faces if required.
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Functional Molded Parts Student Notes:
Shell Properties (2/2) The Core tab is used to understand and resolve the offset error that may occur during the core computation. It displays the list of Shellable features and shows how each feature contributes to the inner shape of the shell. This helps you to change the core type of any Shellable feature in the current functional body Core contribution type: 1.
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2.
3.
Interconnected core (default): Automatically generates the core at the functional body level by computing an offset of the union of all Shellable features contained in the same functional body. Isolated core: Automatically generates the core at feature level by computing an offset of only the Shellable feature geometry (the feature is independently shelled). Note: Faces of features that have an isolated core cannot be later selected as ‘faces to be removed’ in the Shell Properties command. Select core: You can select any Body that will represent the core volume of the Shellable feature.
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Select the type of Core
Functional Molded Parts
Draft Properties (1/2)
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Like the ‘Shell properties’, the ‘Draft Properties’ are important properties of a molded part. Using the ‘Draft Properties’ tool, you can specify the ‘Pulling direction’, ‘Draft angle’ and the associated ‘Parting element’. These set of properties can be applied to any ‘Body’ of the part you design. Draft properties are useful to manage the ‘Drawer-specifications’ (the way the component will be drawn out of the mold). ‘Draft properties’ ensure that proper manufacturing specifications are used in the features.
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Student Notes:
Functional Molded Parts Student Notes:
Draft Properties (2/2) Draft Properties appear in the Draft Behavior field of the Draft tab
' Faces to draft'can be selected by pulling direction.
' Use parting element'option is available to reuse the parting element defined in the draft properties feature as neutral element.
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You can also select the draft properties defined in another solid functional sets.
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All the draft properties which are defined in the FMP part document can be accessed during the feature definition.
Functional Molded Parts Student Notes:
Shell Property Methodology Tips Depending upon the geometry, sometimes the body may not be ‘shellable’. In such cases you can solve the ‘Shellable Feature’- error if any. 1
Edit the shell properties.
If this feature cannot be shelled with the others…
2 If this feature cannot be shelled at all…
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3 Extract or create a surfacic Body. Then select this Body as new core
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Switch from Interconnected to Isolated core.
Functional Molded Parts Student Notes:
To Sum Up You have learned about the basics of Molded Part and the concept and advantages of ‘Functional Molding’ The FMP workbench helps the designer to design the parts that can be manufactured right the first time. CAVITY = outer shape
MOLDED PART
Mold
CORE = inner shape
The two important properties of a molded part are ‘Shell Properties’ and ‘Draft Properties’.
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Wall Thickness
Draft Angle
Face(s) to remove
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Pulling Direction
Functional Molded Parts
Basic Features In this lesson you will learn to define the overall shape of the molded part using 'Basic Features'.
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Introduction to Basic Features Behavior of Basic Features Shellable Feature Other Basic Features To Sum Up
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Student Notes:
Functional Molded Parts Student Notes:
Introduction to Basic Features The Basic Features in FMP are similar to the basic features of Part Design (Pad, Revolve and Sweep). The Basic Features define the generic shape of the the part. Following is the list of Basic Features of FMP workbench:
Solid Functional Set Sketch Plane / Point / Line
Shellable Feature
Added Feature Protected Feature Shellable Feature Internal Feature External Feature
External Feature Core Feature
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Cutout Features
Push Pull Fitting
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Protected Feature
Functional Molded Parts Student Notes:
Behavior of Basic Features (1/3) Basic Features are used to create generic shapes of a Part. Each feature provides a behavior to a basic volume. Modifications in the part contribute to material addition or removal from the core or the cavity or both. Six basic features are available for adding or removing material from the part.
‘Behavior’ is understood as the impacts(s) which the feature has on the mold (cavity and/or core) or on the part.
Impact on Mold
+
Add
–
Remove
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CAVITY
CORE
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Impact on Part
mean
Cavity
Core
External Shape
Internal Shape
–
+
+
–
–
+
–
–
+
+
+
+
–
–
–
+
+
–
Functional Molded Parts
Behavior of Basic Features (2/3) There are five basic modes by which you can define the Shape using any Basic feature Prism Sweep Revolve Thick Surface External Shape
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The behaviors of the features guarantee that each design intent is maintained, irrespective of their position in the specification tree.
In addition to the existing shellable prism, the ‘Shellable Revolve’ inherits the shell values defined in the “Shell properties”.
Result = Behavior (Shell) + Feature (Pad + Revolve)
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Student Notes:
Functional Molded Parts Student Notes:
Behavior of Basic Features (3/3) The ' Change Functional Behavior'contextual command allows you to change the functional behavior of a Basic Feature.
In this example shown below, the ‘Shellable Revolve’ is changed to ‘Added Revolve’.
1 2
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3
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New basic behavior
Functional Molded Parts
Shellable Feature
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You will learn how to use the ‘Shellable Feature’ to define the shape of a molded part.
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Student Notes:
Functional Molded Parts
About Shellable Feature (1/6) This feature creates hollowed shape according to the properties specified in the ‘Shell Properties’ feature.
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By default, the Shellable Feature inherits ‘Shell Properties’, like 0mm thickness, which results in a solid. After editing the Shell Properties, you get the desired geometry.
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Student Notes:
Functional Molded Parts
About Shellable Feature (2/6) Basic features can also include specification for drafts’ and fillets’.
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The ‘Core’ functionality enables you to specify the Core Type for a Shellable Feature. This sometimes becomes necessary if the geometrical complexity of the shellable feature is such that the standard offset fails. You can select the core type from the ‘Core’ tab of the Shellable Feature
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There are three options available for the core type. Interconnected Core Isolated Core Select Core
Student Notes:
Functional Molded Parts Student Notes:
About Shellable Feature (3/6) Interconnected core: If the cores of two adjacent Shellable Features are ‘Interconnected’ then they share the core.
Shellable Feature created using core type as ‘Interconnected’
Second Shellable Feature created with core type as ‘Interconnected’
Result of two adjacent Shellable Features having core type as ‘Interconnected.
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Isolated Core: In the above example, if the core of any one of the two Shellable Features is of the type ‘Isolated’ then the result will be as shown in the image below.
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A wall is created between the volumes of the two ‘Shellable Features’
Functional Molded Parts Student Notes:
About Shellable Feature (5/6) Isolated Core: By selecting the Core type as ‘Isolated’ you can: Prevent the core of the adjacent Shellable Feature from occupying into its core. ( Unlike Interconnected Cores). Specify an alternative value of Shell thickness (other than the previously defined thickness in ‘Shell Properties’) of the Solid Functional Set.
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3.5 mm
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1mm
Functional Molded Parts Student Notes:
About Shellable Feature (6/6) Select Core: With the ‘Select Core’ option you can select an external ‘Body’ as a Core. The result of ‘Select Core’ options is similar to ‘Remove’ Boolean operation of part design.
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Selected Core
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Functional Molded Parts
Shellable Feature Description (1/3) In the Shellable Feature dialog box you can also specify various properties like Draft, Fillets, etc, which can be intrinsic to the feature itself.
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This leads to more robust dress-up in case of design change and also a lighter specification tree.
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Student Notes:
Functional Molded Parts
Shellable Feature Description (2/3)
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The draft tab allows you to define the Draft behavior of the feature (for Prism and Sweep shapes). Drafts are applied on all the faces which are generated from the sketch edges.
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The blue arrow represents a virtual cone that gives the preview of the wall slope. You can reverse the direction by clicking the blue arrow.
Student Notes:
Functional Molded Parts Student Notes:
Shellable Feature Description (3/3) The ‘Thick’ option allows to define a thin volume using a profile. Closed sketch
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Check the thick option to create a thin volume from a profile
The thickness can be managed on either side of the curve by un-checking the ‘Neutral Fiber’ option. The thickness of a thin solid should not be interpreted or compared to the ‘wall thickness’ of the part. These are different parameters which have different applications.
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Open Sketch
The thick is automatically activated when the sketch is open
Functional Molded Parts Student Notes:
Shellable Feature Examples
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Shellable feature based on a Sweep
Shellable feature based on a Surface
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Shellable feature based on a Revolve
Shellable feature based on a Body or a closed surface (planar openings are closed automatically like the part design CloseSurface feature)
Functional Molded Parts
Other Basic Features
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You will learn to use other basic features to define shape of a molded part.
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Student Notes:
Functional Molded Parts Student Notes:
External Feature This feature adds material only to the external shape of the part. As a result, the volume of the feature is automatically trimmed up to the external shape.
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External Feature’s shape can either be prism, sweep, revolution, thick surface or external shape.
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Material that occupies the inner shape of the part gets trimmed automatically.
Functional Molded Parts Student Notes:
Added Feature
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This feature can add material both to the inner and the external side of the molded part. So with respect to core / cavity, this feature can remove material from the cavity as well as the core.
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Material added inside and outside of the part
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Protected Feature
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The Protected Feature is used to cut and protect a volume. Any other FMP feature cannot interfere in the protected volume created using protected feature.
In the above example, we created a rib. But the part of the rib that occupied the protected volume automatically got trimmed due to the behavior of the ‘Protected Feature’
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Student Notes:
Functional Molded Parts Student Notes:
Internal Feature The behavior of this feature is opposite to that of ‘External Feature’. This feature adds material only to the internal region of the part. As a result, the volume of the feature is automatically trimmed to the internal shape of the part.
First radius
Lateral radius
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Extruded profile is trimmed inside the part
With respect the core / cavity of a molded part. This material will remove material from the core.
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Functional Molded Parts
Core Feature
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The Core Feature extends the core volume. It removes material from the wall thickness of the shell. This feature can be used to make cutouts in the ‘thickness’ of the wall and to extend the core volume.
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Student Notes:
Functional Molded Parts Student Notes:
Cutout (1/2) This feature modifies the cavity and the core while respecting the body's thickness or the user-defined thickness.
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Floor Radius
The Cutout feature creates a protected volume.
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Functional Molded Parts Student Notes:
Cutout (2/2) The ‘With Floor’ and ‘Complement’ options control the result of the Cutout feature.
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Cutout With Floor
Cutout Without Floor
The ‘Complement’ option trims the region outside the Protected Volume of the Cutout.
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Functional Molded Parts
Body Modifiers The Body Modifier features use an external body as a tool to deform the part; the deformation volume is protected.
Push feature
Pull feature
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Fitting feature
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Student Notes:
Functional Molded Parts Student Notes:
Push (1/2) Push tool allows you to modify your design by pushing another solid body in the part, using it as a tool. Availability to manage the clearance on faces
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Current active Body
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Functional Molded Parts Student Notes:
Push (2/2) Push adds material to cavity of the part and removes material from the core.
Tool Body
Pushed material Clearance
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You can specify a clearance to provide a gap between the Tool Body and the Part.
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Functional Molded Parts Student Notes:
Pull Pull allows you to modify your part by pulling another solid body in the part. In this case, the solid body is used as the tool. Pull adds material to the core and removes material from the Cavity.
Bottom View
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Here, you have the option to protect or unprotect the Pull volume.
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Functional Molded Parts Student Notes:
Fitting Fitting allows you to cut the shape by fitting an external ‘Body’ into the part. This behavior is similar to the Protected feature.
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Clearance Option
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Functional Molded Parts
About the Functional Set ‘Functional Set’ is an organization feature which is similar to ‘Geometrical Set’. It can be used to define a group of functional features. It can not only contain functional features but also sketches, wireframe and surface features. A functional set can be the ‘In Work Object’. It is the insertion position for new functional and wireframe features. Reordering of features between and inside functional sets is possible.
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The Functional Set feature provides a full capability to organize and manage specification tree in order to group features by function to capture the design intent in an organized way.
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Student Notes:
Functional Molded Parts Student Notes:
To Sum Up (1/2) You have learned the use of ‘Basic Features’ to define the overall shape of the part. You have seen the behavior of ‘Shellable Feature’
You have seen the following ‘Basic Features’ and their behavior with respect to the inner and outer side of a molded part.
Shellable Feature External Feature
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Added Feature
Internal Feature Core Feature
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Protected Feature
Functional Molded Parts Student Notes:
To Sum Up (2/2) Basic Features Sum Up Continued….
Tool Body
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Clearance
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Push
Pull
Fitting
Functional Molded Parts
Functional Features Using the 'Functional Features', you will learn how to define shapes (of a molded part) that have a function to perform.
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Basic Behavior of Functional Features Rib Feature Example Rib Feature Other Functional Features To Sum Up
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Student Notes:
Functional Molded Parts
Basic Behavior of Functional Feature Functional features have a behavior which is more manufacturing process-oriented than the basic features. Functional features are defined on the basis of ‘Assembly’ and ‘Manufacturing’ processes of the injection molded parts. Every Functional Feature has a specific design intent that is catered by some behavior.
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Drafted Rib defined with a profile
Rib cut by one protected feature
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Student Notes:
Functional Molded Parts Student Notes:
Rib Feature Example A Rib of a molded part has a design intent which is satisfied by behavior of the ‘Rib Feature’. Behavior: The part of the rib that goes outside the ‘Shelled’ body gets automatically trimmed.
Design Intent: Ribs are to be drafted by some angle to provide a relief when the component is ejected out of the mold
Behavior: The Rib feature can apply a draft to the rib walls.
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Design Intent: Rib has to be typically applied inside the shelled body
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Functional Molded Parts
Rib Feature
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You will learn the ‘Rib Feature’ and its functional behavior.
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Student Notes:
Functional Molded Parts
What is a Rib Feature
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A ‘Rib Feature’ is an FMP feature used to create the Ribs in a molded part. The input ‘Sketch’ for Rib feature is simply a set of curves. Other properties related to a Rib like ‘Thickness’, ‘Draft’ etc can be specified in the Rib Feature dialog box.
The behavior of the Rib feature is such that it automatically gets trimmed to the ‘Shell’.
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Student Notes:
Functional Molded Parts
Other Functional Features
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You will learn the use of other functional features to create or modify the geometry of a molded part.
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Student Notes:
Functional Molded Parts Student Notes:
Pocket (1/2) The Pocket feature deforms the active body like a machine tool pushing the extrusion of the profile into the body. This feature also builds walls around the profile as shown.
Floor Radius
Lateral Radius
Rib from the core enters the pocket
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In the above example it is interesting to note that the ‘Rib’ which was defined in the core has entered into this pocket from the bottom. This is because the Pocket Volume is not ‘Protected’ by default. You can make the volume of the Pocket protected by selecting the ‘Protected Volume’ option.
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Functional Molded Parts
Pocket (2/2)
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The ‘Only Outside’ option creates the pocket outside the ‘Shelled Volume’
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Student Notes:
Functional Molded Parts Student Notes:
Boss Boss Feature is similar to the Shellable Feature. It extends the external shape of the part by removing material from the cavity and adding it to the core.
Drafted and filleted boss.
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Availability to limit the boss on a plane or a surface
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Functional Molded Parts Student Notes:
Rest (1/2) This feature creates an flat horizontal surface for resting of some other component(s). It modifies both the core and the cavity volume.
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Landing: horizontal zone generated for the rest.
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The region in space normal to the flat surface is protected infinitely because an external component will be resting in this region. So it is intentional that this region does not have any solid material in between.
Functional Molded Parts
Rest (2/2)
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By default the ‘With bottom’ option is checked. You can uncheck the ‘With bottom’ option of the ‘Rest’ panel to have a bottomless Rest.
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Student Notes:
Functional Molded Parts Student Notes:
Grill (1/2) A grill is usually used to create a mesh pattern in the thickness of a shelled body. To create a grill, you need a profile that defines the external boundary as well as the internal components, such as the internal island, ribs and the spikes. Island
Boundary
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Ribs
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Spikes
Functional Molded Parts Student Notes:
Grill (2/2) The profile for each specification (boundary, ribs, spikes, island) can be defined by different sketches.
If you have defined a single sketch for all, then you will have to use the contextual menu ‘Go to profile definition’ to select profiles for the feature.
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Clicking the ‘>>’ key will display the helping pictures, which give details about specifications of the feature.
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Helping Pictures
Functional Molded Parts Student Notes:
Reinforcement Reinforcement is usually used to add strength to the molded part. But unlike the Rib, it adds material to the external shape of the molded part.
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Width of Reinforcement Do not confuse Reinforcement to be like a “Rib on the outer shape”. It is NOT so. Reinforcement is a hollow feature and not a solid feature like rib. The ‘Section View’ shown below will give you an idea about its shape.
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Functional Molded Parts Student Notes:
Hole This feature defines a cylindrical protected volume. To create a hole you need to first define its position, and then its dimensions. 1 Select the Hole Tool.
2 Select a face
3 Edit the Positioning Sketch and create two dimensions to position the center point.
5 Modify the distance of the hole’s center as shown and click OK.
4
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3
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4 Modify the hole’s definition.
Functional Molded Parts Student Notes:
To Sum Up You have learned the use of Functional Features to create some specific shapes in the molded part. You have seen how ‘Rib Feature’ satisfies the ‘Design Intent’ and function of a ‘Rib’ in a molded part.
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You have also seen the use of the following ‘Functional Features’ and the way they create shapes which perform some function in the molded part.
Pocket
Boss
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Grill Rest
Reinforcement
Functional Molded Parts
Feature Modifiers and Dress-Up Tools You will learn how to use 'Feature Modifiers' and Dress-Up tools to modify the shapes that are created by 'Basic Features' and 'Functional Features'.
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Introduction to Feature Modifier Feature Modifiers in Brief Remove Feature Other Feature Modifiers To Sum Up
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Student Notes:
Functional Molded Parts
Introduction to Feature Modifier (1/2)
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A Feature Modifier is used to modify ‘Functional Features’. You can use a Feature Modifier to act only on selected Features.
In the above example, even when the sketch overlapped some region of Shellable Prism.3, it did not remove material because the Remove Feature acted only on Shellable Prism.2.
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Student Notes:
Functional Molded Parts
Introduction to Feature Modifier (2/2) The modification done by a Feature Modifier assures that the behavior of the Functional Feature is maintained.
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For instance, a Cut in a Shellable Features not only removes material, but also maintains its Functional characteristics.
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Student Notes:
Functional Molded Parts
Feature Modifiers in Brief (1/2)
Cut Feature: Trims the shapes of a set of selected features of the active body by using surfaces or planes, while maintaining its shell properties (wall thickness). Remove Feature: Modifies one or more features by removing a shape from it.
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Intersect Feature: Computes the intersection of the shape you define with the features you want to modify (complementary of remove).
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Transformation Modifiers: Duplicate a set of selected features
Functional Dress Up Features: Compute a Fillet/Chamfer/Draft on internal edges/faces of the functional features. If the volume is shelled, the fillet is propagated into the shell.
Student Notes:
Functional Molded Parts
Feature Modifiers in Brief (2/2)
The red symbol on a feature in the specification tree means that the feature has been modified by a ‘Feature Modifier’.
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In the above example, the ‘Shellable Revolve.1’ is modified by ‘Cut.1’ and ‘Cut.1’ is in turn modified by ‘Remove Revolve.2’. So there is a red symbol on ‘Shellable Revolve.1’ and ‘Cut.1’.
Note that there is no red symbol for ‘Cutout.1’ because ‘Remove Revolve.2’ does not modify ‘Cutout.1’
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Student Notes:
Functional Molded Parts
Remove Feature
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You will learn the use of Remove Feature to remove material from a Shelled Part, maintaining the ‘Shelled’ behavior of the Part at the same time.
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Student Notes:
Functional Molded Parts
What is Remove Feature Using the Remove Feature, you can modify the shape by removing material from a shape. Remove Feature maintains the functional behavior of the feature on which it acts.
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‘Remove’ using ‘Sweep’
Shell behavior maintained.
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Student Notes:
Functional Molded Parts Student Notes:
Remove Vs Cutout The Remove Feature is somewhat different as compared to the Cutout Feature. Cutout
Remove
The region of Cutout is Protected
The important difference is that the region created by Remove Feature is not Protected.
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Facility to Specify the Feature(s) on which remove will act
Also, in Remove Feature you can specify the feature(s) on which you want the Remove feature to act.
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Functional Molded Parts
How to use a Remove Feature (1/2) 1
Student Notes:
Click the ‘Remove Feature’ tool.
2
2
Select the Features to be modified by the ‘Remove Feature’.
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To select multiple features, you can use the button (as shown below) of the Remove Feature dialog box and select multiple features. This dialog box will list the features that you select.
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Functional Molded Parts
How to use a Remove Feature(2/2)
3
Select the ‘Shape definition’ that you want to use for the Remove Feature.
4
Select the inputs for the ‘Shape definition that you have selected in the above step.
Student Notes:
3
4
4
Click OK.
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5
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Functional Molded Parts
Other Feature Modifiers
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You will learn about some additional Feature Modifiers and the way they interact with Functional Features.
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Student Notes:
Functional Molded Parts Student Notes:
Cut Feature
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Using this feature, you can trim the desired features using a cutting surface.
You can also specify the fillet radius for the edges formed by the intersection of the part with the cutting surface.
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Behavior is maintained
Functional Molded Parts Student Notes:
Intersect Feature
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The Intersect feature works like Boolean operation giving you the result of intersection of selected features with the ‘Shape definition’ that you specify.
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You can specify the ‘Intersecting Radius’
Functional Molded Parts
Pattern feature
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The pattern feature is used to duplicate Functional Features.
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Student Notes:
Functional Molded Parts
Functional Fillet / Chamfer / Draft
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The Functional Dress-Up features (Functional Fillet / Chamfer / Draft ) are used to modify the geometries ( Edges / Faces ) that are created only by the Functional Features.
Outer Edge selected for Functional Fillet.
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Corresponding inner edge automatically filleted to maintain the ‘Shellable’ behavior
Student Notes:
Functional Molded Parts
Part Design Dress-Up Features Some Part design fillets have to be added at the end of the FMP design. These part design fillets are necessary only for edges that are formed by the intersection of two functional features.
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Edge Formed at the intersection of two Shellable Prisms
These Part Design Dress Up Features are listed after FMP features in the specification tree and are NOT a part of the ‘Solid Functional Set’
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Student Notes:
Functional Molded Parts Student Notes:
Edge Fillet – Propagation Options Using the ‘Edge Fillet’, you can use the various propagation options to fillet the edges resulting from intersection of a feature and core / cavity or any other feature.
Rectangular Corner Design
Corner design changed to triangular – Fillet remains intact.
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These options make the fillets robust and stable and can withstand any major design change
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Functional Molded Parts Student Notes:
To Sum Up You have learned the use of ‘Feature Modifiers’ and ‘Dressup’ tools which are used to modify the shapes created using ‘Basic Features’ and ‘Functional Features’. You have seen the following ‘Feature Modifiers’ and Dress-Up tools.
Cut
Transformation Features
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Remove Functional Dress Up Features Intersect
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Functional Molded Parts
Multi-Body Features In this lesson, you will learn about the ‘Multi Body’ approach in FMP. You will see the following topics in this lesson
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Multi-Body Approach with FMP Divide Feature Lip Feature Flange Join Feature Snap Lock
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Student Notes:
Functional Molded Parts Student Notes:
Multi-body Approach with FMP The Multi-Body Features are used for creating shapes in two bodies such that they Fit / Lock in each other.
Cap
Bottle
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Multi-Body Features modify the existing FMP Body in such a way that: It splits the Body into two Bodies. Modifies the shape of both the split Bodies so that they Fit / Lock in each other.
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Multi Body Feature: ‘Lip’
Section View
Functional Molded Parts
Divide Feature (1/2) The Divide Feature Splits the Body using a ‘Surface’ or ‘Plane’. This parting element is usually the ‘Parting Surface’ of the mold environment.
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Parent Body
The ‘Keep both sides’ option allows you to retain both the resulting divided bodies.
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Student Notes:
Functional Molded Parts Student Notes:
Divide Feature (2/2) After the Creation of Divide Feature, the original Body gets hidden and two additional Bodies get created in the Specification tree.
Parent Body
Parent Body modified
Children Body(ies) ‘Updated’
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Modifications in the parent body are propagated to the children.
Child Body modified
Parent Body ‘Unaffected’
However modifying the child does not propagate the changes to the parent.
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Child Bodies
Functional Molded Parts Student Notes:
Lip Feature (1/2) The Lip Feature generates the two sides of the lips between two divided bodies as shown in the Figure.
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The default lip path is a set of edges provided by the Divide feature. By default, all divided edges constitute the path.
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Path for the Lips
Functional Molded Parts
Lip Feature (2/2)
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The ‘>>’ button of the Lip panel opens the ‘Helping Pictures’ which clearly guide you about the various parameters of the Lip Feature. The helping pictures change according to the method of the Lip that you select.
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Student Notes:
Functional Molded Parts Student Notes:
Flange Feature (1/2) The Flange Feature adds material of a constant thickness in the two bodies around the edges that get created by the ‘Divide’ feature.
Edges Created by Divide Feature.
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If you ‘Divide’ the body along the surface, then the ‘Flange’ will be created accordingly.
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Functional Molded Parts Student Notes:
Flange Feature (2/2) The helping pictures help you to understand the various parameters of the Flange Feature.
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Dividing Element: The Surface
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The difference in behavior of the Pulling Direction option of the Flange Feature can be noted from these two images.
Functional Molded Parts
Join Feature The Join feature is used to create space for joining elements like Screw, Nut etc. which join the two bodies.
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The Join Feature is driven by the parameters of the Screw / Nut that it has to accommodate. The number of parameters for the join is quite high, hence, a wide flexibility in the design is possible.
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Student Notes:
Functional Molded Parts Student Notes:
Snap Lock Feature (1/3) The Snap Lock Feature is used to create Snap-Fit pair of attachments in two bodies that fit into each other.
Projection (Clip)
Cutout (Trap)
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Broken Section
This Feature creates a Projection in one body and corresponding cutout in other body such that they mutually fit and lock.
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Functional Molded Parts
Snap Lock Feature (2/3)
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This Feature requires an axis system. The shape and its parameters are oriented with respect to the Axis System.
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Student Notes:
Functional Molded Parts
Snap Lock Feature (3/3) The helping pictures show the parameters in detail.
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Use the ">>" button of the ‘Snap Lock’ dialog box to display helpful pictures for the ' Snap Lock Feature'definition parameters.
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Student Notes:
Functional Molded Parts
To Sum Up (1/2) You have learned to create ‘Locking’/’Fitting’ shapes in two bodies using the “Multi-Body Features”.
The ‘Divide Feature’ splits the body into two bodies using the splitting element.
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The lip feature creates lip between the two bodies that are split using ‘Divide Feature’
The Flange Feature creates a flange around the parting edge of the two split bodies.
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Student Notes:
Functional Molded Parts
To Sum Up (2/2) Continued…..
The Join Feature creates space in the two bodies for accommodating a fastener (between two bodies).
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The ‘Snap-Lock’ feature creates a Snap-fit pair in the two bodies.
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Student Notes:
Functional Molded Parts
Extraction Features You will learn how to extract the mold ‘Core’ and ‘Cavity’ and other inserts from a molded part that is designed using specific FMP features.
You will see the following topics in this lesson
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Extraction - General Process Core Extraction Cavity Extraction Cavity/Core Extraction – Methodology tips Extraction Properties Volume Extraction Behavior Extraction Feature
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Student Notes:
Functional Molded Parts Student Notes:
Extraction General Process
1 Extract basic Core and Cavity Bodies
Molded Part defined
3
Refine Core and Cavity Bodies definition
4 Create additional inserts or tools
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5 Reroute fillets from the main PartBody to the Cavity Bodies (copy dress-up feature from the Part to the Cavity/Core extraction)
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6 Shrink Core, Cavity Bodies and additional Insert
2
Create Added Features to materialize the Mold Plates
Functional Molded Parts Student Notes:
Core Extraction The Core Feature extracts the Core volume from a Body containing the ‘Solid Functional Set’. This extraction is completely associative to the Part Body and any changes in the Part Body are automatically reflected in the Core.
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New Body
A new Body with a Solid Functional Set gets created in the Specification tree.
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Functional Molded Parts Student Notes:
Cavity Extraction The ‘Cavity Extraction’ Feature extracts a ‘Protected Volume’ for the Cavity. This extraction of the ‘Protected Volume’ is associative to the ‘Solid Functional Set’ from which it is extracted.
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Protected Cavity Volume Created
This ‘Protected Volume’ of Cavity when subtracted from a ‘Cavity Plate’ (created using ‘External feature), gives you the desired Cavity.
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Functional Molded Parts Student Notes:
Cavity/Core extraction – Methodology tips In the Core and Cavity extraction, you can exclude features from getting extracted into the Core and Cavity For Example: A Rib is usually not extracted in the Core. To achieve this, you can specify the Rib to NOT be a part of the the Core extraction.
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Rib Included in the Core.
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Rib Excluded from the Core Extraction
Functional Molded Parts
Extraction Properties (1/2) Using the ‘Extraction Properties’ tool, you can assign the ‘Protected Features’ to the Core or Cavity. Depending upon the property(ies) of ‘Protected Volumes’(draft angle), you can assign the ‘Protected Volumes’ to be a part of Core or Cavity.
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Protected volume to be assigned to Core OR Cavity
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According to the draft angle, the user can assign Protected Volumes to the core or to the cavity.
Student Notes:
Functional Molded Parts Student Notes:
Extraction Properties (2/2) Extraction properties are added to the functional description of a Part These Extraction Properties are available in the ‘Extract Core’ or ‘Extract Cavity’ panel.
Extraction Properties.1
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Part with Protected Prism assigned to Core
Resulting Core
The Core / Cavity get extracted as per the ‘Extraction Properties’ when you select the ‘Extraction Properties’ in the ‘Extract behavior’ drop box of the ‘Extract’ panel.
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Functional Molded Parts
Volumes Extraction (1/2)
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The ‘Volumes Extraction’ command is used for extraction of ‘Electronic Discharge Machining’ inserts for Grills and other protected Volumes.
After extracting the Grill Body, you can add material to form the complete electrode of the ‘Electronic Discharge Machining’ tool which will be used for the Grill.
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Student Notes:
Functional Molded Parts
Volumes Extraction (2/2) Just like Grill, you can also extract other protected volumes.
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Extracting Volumes from ‘Features’
Extracting Volumes from Body will extract all the ‘Protected’ volumes. (Holes and Protected Features)
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Student Notes:
Functional Molded Parts Student Notes:
Behavior Extraction Feature The Behavior Extraction Feature is used to extract the Functional behavior of any feature. This feature is usually used to duplicate associatively a Function volume into a new ‘Body’ for changing its behavior for some specific requirement(s). For example, a protected cutout can be used to form the ‘Electronic Discharge Machining’ tool. 1
2
3
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4
In the above example, a ‘Protected’ behavior or Protected Prism.7 has been duplicated in a new Body to change its behavior to form the electrodes of the ‘Electronic Discharge Machining’ tool.
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Functional Molded Parts
To Sum Up You have learned techniques of extracting ‘Core’, ‘Cavity’ and other ‘Electronic Discharge Machining Inserts’ using the Functional Extraction Features. The ‘Core’ directly gets extracted by the ‘Core Extraction’ tool.
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However the cavity is extracted as protected cavity volume. Subtracting the cavity volume from a solid plate (created by ‘External Feature’) gives the desired cavity.
Using the ‘Volumes Extraction’ tool, you can extract ‘‘Electronic Discharge Machining Inserts’ for Grills and other protected features. Using the ‘Behavior Extraction’ tool, you can duplicate a feature and change its behavior if required.
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Student Notes:
Functional Molded Parts
Course Summary (1/2) In this course you have learned to design a molded part, using specific ‘Function Oriented Features’. You have also learned to extract the ‘Core’, ‘Cavity’ of the parts. You have seen the use of ‘Basic Features’ to define the overall shape of the part. You can now correctly choose a feature to modify the internal or external shape of the molded part.
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You have also seen the use of ‘Functional Features’ which create / alter shapes that have certain function to perform.
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Student Notes:
Functional Molded Parts
Course Summary (2/2) You saw the use of the ‘Feature Modifiers’ and ‘Dressup’ tools which modify the shape of the part and maintain the functional characteristics at the same time.
You learned the “Multi-Body Approach” in FMP and used tools such as, ‘Snap-Lock’, ‘Flange’ and ‘Lip’, which create locking / fitting shapes simultaneously in two bodies.
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You learned to extract the ‘Core’, ‘Cavity’ and ‘EDM Inserts’ for the molded part that you have designed, using FMP workbench.
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Student Notes:
