ZW3D

Mold and Die Training Guide

Only for Prefessional Version&Prenium Version

Copyright and Trademarks

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ZW3D V2010
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Mold & Die V14

page 1

Table of Contents
Forward ........................................................................................................................................... 3
Chapter 1

Importing and Creating Geometry ................................................................................ 4

Chapter 2

Analysis, translation, and scaling.................................................................................22

Chapter 3

Creation of Core, Cavity and Parting Planes ...............................................................36

Link Manager ..................................................................................................................................62

Chapter 4

Creating your first insert ..............................................................................................70

Copy Insert to the Core ...................................................................................................................80

Link Manager ..................................................................................................................................81
Chapter 5

Creating your second insert .........................................................................................88

Copy Insert to the Core ...................................................................................................................95

Link Manager ..................................................................................................................................96
Chapter 6

How to create Sliders ..................................................................................................99

Copy Slider to the Cavity ..............................................................................................................102

Link Manager ................................................................................................................................107
Appendix A

2D Drawing Layout .................................................................................................109

Appendix B

Mold Base Creation ................................................................................................116

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Mold & Die V14

Forward
The full version of the ZW3D documentation is available online by selecting Help Browser
from the ZW3D Help Menu.. You can also browse all ZW3D online documentation in HTML
format directly from the ZW3D CD. Go to the "\ZWSOFT\ZW3D 2010 Eng\doc"
Eng
directory on
the ZW3D CD using Windows Explorer and open the file ZW3D.chm.
.
This Mold & Die Training Guide is available as a printed manual and in PDF format. To view
or print the PDF version, install the Adobe Acrobat Reader (provided on the ZW3D CD in the
Acrobat directory) and open the corresponding files in the \ZWSOFT
ZWSOFT\ZW3D 2010 Eng\PDF
directory on the CD. Refer to the On-line HELP for information relating to specific tasks (e.g.,
Creating and Editing Parts, Sketch Dimensions, Constraints, etc.).
NOTES:
1. For best results, view and print the PDF version of the documentation using the Adobe
Acrobat Reader.
Traini
Guide is only a portion of the complete documentation,
2. Since the Mold & Die Training
it is highly recommended that you utilize the On-line HELP.. You will find additional
topics, more information on command options, input options, additional command notes,
and cross-links
links to related tasks and topics.
3. It should be noted that the On-line HELP will always be more up-to-date
up
than any
printed or PDF material. If you find any discrepancies between the two, always refer to
the online documentation.
4. ZW3D's Help Interactive Mode allows you to view the online documentation
simultaneously while you are working. It will automatically load topics as you select new
commands.

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Chapter 1

Importing and Creating Geometry

NOTE: This exercise is done in MM Units. It would simplify things if you were to edit the
configuration, set your default units to MM and add a default part template called
PartTemplate(MM). You should see this template on the Create new (Part) menu but you
wouldnt have to pick it each time we create a new part object.

Lets create a Multi-Object file called

Project_554.Z3.
Create an Part object called
01_IGES_001.

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Now that we are in the part,, we can verify what units we will be working in.
in To do that, we will
select Edit on the Utilities toolbar and then the Preferences option.

The default system tolerance is 0.01 and we will keep that value for this exercise.
The Part settings menu allows us to configure:
Units Option that allows the user to define work units.
Show Back Facing Edges Option
Option that allows the user to see the hidden
edges of the model as dashed lines or continuing lines.
Alternate Display of Free Edges Option thatt allows visualization of
openings and Gaps in the 3D model.
Auto Sew On Face Creation Option that indicates if the new faces created
by the user are automatically sewn to the active model.

Whenever you have a Boolean Operation type, holes on surfaces or

openings across two objects, they can be joined as one or kept separate.

**********NOTE: On the Part Settings menu, it is

recommended to turn Auto Sew off allowing the
t user to
analyze
alyze the geometry after importing.

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Chapter 1 page 5

Now, lets import an IGES file. To do that, select, File and go to Import.
This opens the IGES
Import dialog so that
you can definez
settings for the file that
you are importing. We
will select the IGES
option for importing.

In IGES Import
Settings it is possible
to define import
parameters by
choosing the Set IGES
Options button.
Auto Sew Geometry
Indicates if the
geometry is to be
automatically united.
Rename layer
collisions Renames
the layers if they
already exist with the
same name.

55
11
66
44
77

Auto activate part Indicates that after

importing, the geometry is automatically
activated. This command is only necessary if the
importing is done at the object level of the work
session.

Remove duplicate surfaces If there are duplicate trimmed surfaces, the duplicate is thrown away.
Break trim edges - Will analyze the edges of the surface and break the edges on the tangent
points if needed.
Reset Dependencies - It is not uncommon for third party IGES files to contain incorrect
dependency flags causing entities to not import, or to import more than once. Use this option to
flushes the dependencies reported in the file, and recreate them based on the entity
references from the parameter section of the IGES file.
Drawings Import the 2D lay-outs included in the file for the 3D environment.
Bounded planes Import planes with limits.
Unbounded planes Import planes without limits.
*********NOTE: For this exercise, deactiveate the Auto Sew Geometry option and select
OK on the Options menu.

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importing Select the Filter optionss as shown.

shown
Select the Filter settings for importing.

This menu lets the user define the type of geometry to be imported.
Select OK.

Select OK and select the file Backcover_

Backcover_554_Rev_04.igs,, which is located in the
\ZWSOFT\ZW3D 2010 Chs\training
training installion directory.

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Chapter 1 page 7

After you have finished importing the IGES file, the object should look like this:

Your model has all the edges of the surfaces dashed, because they were not sewn during the
import.
The Quality of the imported geometry can be improved by healing.
Select the Heal Tool Tab. Select the command Heal Part Topology as shown in the figure
below.

This command defines the tolerance for correction. Keep the tolerance at 0.01 for now.

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The image below shows some examples of problem geometry.

During the import we deactivated the auto sew command. Now lets join the faces using Sew.
To do this we need to display the Free Form Tool Tab as shown below
below. The icons on this tab
are the tools for the building and manipulation of individual surface
surfaces. Refer to the online help
for more about each command.

A few commands are described below.

N-Sided Patch: Use this command to create a face by patching across 3 or more profiles.
The profiles can be wireframe geometry, sketches, or face edges. Required inputs include the
profiles to define the patch.
Intelligent Blend: Use this command to create an intelligent blend face. Required inputs
include the curves, edges, or faces that the new face will start from, go to and pass through.
Optional inputs
puts include using curves, faces or a datum for spine control, circular and conic
cross-sections,
sections, sewing, capping and the ability to give the face a unique name if desired.
Set Face Isolines: Use this command to set the number of isolines displayed in the U
and V directions of a face. You can also set isolines with the Modify Face command
command.
Explode Faces: Use this command to separate faces from a shape. Use the Group
option to maintain the connectivity of the explode faces (i.e., they become a separate shape).
Use the Sew command to join faces back into a shape
shape.
Trim to Faces: Use this command to trim away part of a face or shape where it intersects
with other faces,
s, shapes, and/or datum planes.
Extend a Face: Use this command to extend one or more edges of a face. First select
the face. Then select the edges to extend and enter the distance to extend.

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Select the Sew command.

Select OK to select all faces. You can change the value of the tolerance to be different from
that of the Part Tolerance. Dont change it at this time.
Suggestions to help determine the scope of the needed repairs:
1. Put your Pick Filter on Shape. Window pick the entire screen.
The message window will report how many separate shapes have been imported.
2. Right-click on the biggest shape that highlights and pick Attributes. Change the face
color to the darker of the two light blue colors. This way you can visually see the other
shapes and it also may give you an immediate idea of how to approach the repairs. You
could also temporarily blank this shape to see whats left.

Your model should have most of the edges sewn. Do you notice the difference in appearence
between the sewn edges and the open edges?

Whenever the surfaces are missing or have

Gaps, the edges will be blue and dashed.

After sewing, the system will give you information about the largest Gap existing on the
geometry. The user can refer to that value to redefine the Sew command using it as the new
tolerance. You can use the Heal command again to correct the geometry with the intended
tolerance. W e will do this after we are finished repairing the model.
U

***********NOTE: Since the majority of faces have been joined by sewing, turn the Auto
Sew option back on under Edit > Preferences.

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Use the command EDIT > EDGE > Concatenate.

OK
This will find colinear edges and combine them into one.
Make this command a regular part of your everday Healing
Creating the missing surfaces is the next step.
For this exercise lets use the
Trimmed Plane command. This
command permits the construction
of surfaces from 2 or more edges
and/or curves.
Select edges shown in the image.
<middle-click>
> to accept the
edge selections.
> again to finish the
<middle-click>
command.

For the next surface we will use another command which

will also allow us to create a surface on the free edges.
edges
These tools are found on the Heal
Heal toolbar.

The bottom faces of the

pockets are missing.
mis
When the
part is shaded, the red face you
see is actually the inside of the
back face of the part.

To verify that a face is missing

as opposed to a face that has
its normals reversed, zoom in
close to one of the edges and
window pick the edge and
an look
at the message window. Your
Filter must be set to Edge.
This will give you a count of the
edges found. One edge means
a face is missing.

Select the Fill

Fill Gap between
edges with a new face
command. Select an open edge
and then <middle-click>
> to fill
and confirm.

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Chapter 1 page 11

This menu also contains a command which helps us detect problems with the geometry.
Select the command Show Open Edges. This command lists the number of free edges. It
also displays a form, which allows you to Zoom To to better identify the problem area.

Now we will show you how to solve the problem. In this situation we can use the command
Trim to curves. To use this command, first select the surface to be trimmed. Next select the
edges/curves for that trim. (Use the edges shown in the image). Finally, indicate the side you
wish to keep.
Face

Edges Pick 6

Chapter 1 page 12

Keep area

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Trimming a surface does not automatically sew. S

Select the Sew command, and select OK.

Use the Fill Gap command to create the next surface and select an edge.
This is shown in the image below.

A new surface should be created and automatically sewn per the Preferences setting.

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Find the problem area shown below. Select the Ruled command, for the construction of this
surface. Just select the two edges as shown in the image. Select both edges on the same end
to avoid creating a twisted surface. (generally referred to as a bow-tie effect)

The Ruled command will not only create flat surfaces, but will also create surfaces supported
by two curved edges. Select the arcs as shown in the image below. This type of surface
creates straight line rulings between each point on the two curves selected.

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Once again use

se the command Inquire Open Edges to locate the open edge shown on this
image.

After locating the problem, use the Fill Gap command. Activate
ctivate all of the available tangency
options as shown. Select
elect one of the edges. You will now see a new surface that is tangent to
the surfaces from which it originated.

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Now we are going to repair the surface shown in this image by using the Trim to Curves
command.

Select the surface to be trimmed.

(You may have to change the filter to
FACE)

Select the boundary edge (use <shiftpick> to chain select the edges).
Finally select the side of the face to keep.

Again this surface was trimmed.

Sew and select OK

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The next surface will be repaired by extending

exte
and trimming. Use the Extend Face command
on the Free Form toolbar. Select
elect the open edge of the planar surface (on
( the right) to extend.
Select an extension value of 0.5
0.5. (If you extend the exact distance with the sew option
checked you can skip the next two commands.)

Now trim the surface to the edge which will be the boundary.

Guess what?

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If you verify the openings on the model again, you will see one of two possible results. If after
the initial sew command you sewed again with the tolerance equal to the largest gap, you will
have a solid with zero open edges......youre done.
If you did not select that command you will have two edges left that do not match.

To easily repair the fault in the geometry use the Extend faces to close gap between edges
command. Just select two of the edges that need repair. The software will only select open
edges so you dont have to be real accurate picking.

If you analyze the model again, you can verify that it is completely closed. However, the model
does not have to be completely closed to continue the project in ZW3D.

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Turn on Shade. Change the pick filter to Shape. Run the cursor over the edge of the part.
Attributes Change the Face color or select OK for the default.
Right-Click and select Attributes.
Run the cursor over the edge again. This will show us that we are still missing something.

Using Blank, Unblank and Swap entity visibility

v
you will see that a solid was left in the
model that needs to be subtracted.
We can use Combine Shapes with the Remove option as suggested in this image.

Select the mold part as your base.

base Select the object shown in the image as the object to be
removed.

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Chapter 1 page 19

To complete the repair on the model we just need to heal by selecting Heal part topology
with a tolerance of 0.005.

This will complete the import and repair of your model.

Save your file.

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Mold & Die V14

Chapter 1 page 21

Chapter 2

Analysis, translation, and scaling

After finishing the repairs on the imported part, the next step is to the analyze for draft angle
violations and reposition the model.

Create a new Part at the object level and give it the name 02_Part_Scale_&_Position.

Use the Insert Component command found on the right mouse button menu.

The menu will present you with options that allow you to select a
part to be inserted on the activated part.
Choose the object 01_IGES_001
Check the box next to Anchor component
Position it at 0,0,0
Remember, you can type ,, or type one zero and hit <enter>
on the keyboard.

Zoom All is necessary because the part is not centered on (0,0,0).

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You must use the Merge command available on the Shape tool tab and select the component
so that the object will become local. This way the surfaces also belong to this part. The
Component will become Real
Real Geometry.
Geometry The component itself is not deleted but the
instance of the component in the active part is
is.
The Merge option is also found on the right mouse button menu when the component is
highlighted. (Pick filter should be set to All or Component)

Lets analyze the draft angles.

Mold & Die V14

Open the new Inquire tool tab.

Chapter 2 page 23

By using the Draft Checking mode of the Analyze faces command its possible to verify the
existing draft on the 3D model. It also allows us to more clearly see which faces belong to the
Core and those that belong to the Cavity.
Select the Draft Checking icon from the Required Inputs section and then select the
Direction option. Now right-click in the graphics window and select the option Face normal.
Select the face as shown in the image. Right-click again picking On Entity and then select
any point on the face.
The default direction is +Z but this part has not been oriented correctly yet.

The optional inputs allow you to vary the

direction and draft angle to verify. For the
draft angle enter 2 or use the slider provided.
The gray surfaces are at exactly 2 degrees.
The green surfaces are OK.
As you rotate the part slightly you will see the
surfaces at the right are purple. This
indicates that the draft angle is less than 2
and these surfaces need repair. You should
find 5 on each side of the part including the
hole.

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Based on this analysis, we will correct the draft angle of these faces. Select OK at the bottom
of the options form.
********NOTE: The display has been set to Analyze mode. You can correct the draft while still
in this mode. To change it back to Shade mode select View > Shade from the top menu.

You will correct the face angles.

angles
Select the Draft command from the Mold and Die tool tab. Select the filter option
op
Edge.
Select the edges shown on the
e image below on both sides of the part.

Set the angle value to -2. Select the top of the ribs as a
reference plane.

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Chapter 2 page 25

If you analyze the model again at 2, it will verify that the faces have been corrected.

Now change to regular shaded mode.

Save your file.

The next exercise will use some of the Mold and Die tools.

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The first tool we are going to use is called Create extruded stock. This
his tool allows you to
create a block by the maximum boundaries (limits or edges) of the part.. It will be used to
create a datum needed to help in repositioning the part.
plan of orientation of the block.
bloc Select the same
Select the part and indicate the flat face as a plane
face used for the draft analysis
analysis.

This menu shows the maximum dimensions of the block which envelopes your part.

Toggle the Side Increment to 1 and back to 0 to see the values shown. Side Increment is a
round off value. A value of 1 rounds the numbers to the nearest mm. This techniq
technique can be
used for estimating and ordering material.

Select OK or <middle-click>
> to finish.

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Chapter 2 page 27

Lets now create a datum plane on the top face of the block. Later well use this as a reference
position of the part.
Select the option Insert Datum found on the right mouse button menu.
Select the face indicated in the image.
Change Z- angle to 180 to get the same orientation shown.
<middle-click> for offset of zero.

To place it, select the Origin option found on the menu.

Entity filter on ALL
Right-click Critical
Right-click Between

Select the two points shown in the image.

<middle-click> to accept the default percentage of 50

<middle-click> to finish the command.

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We are finished with the Stock. Erase the stock shape.

Lets position your part in the workspace.

workspace
This positioning has to be done by align
aligning the plane we just created and the XY datum.
Use the command Move entities
ties by aligning frames
frames.
The terms: Datum, plane and
frame all mean the same thing.

Select your part as the object to be aligned

aligned. Filter on SHAPE.
To align the planes first select the datum plane we just created.
You can pick the plane in the graphics window or
click on the History Manager button
Pick the Input Manager
command.

then pick Plane1 from the list.

to return to the

Do the same thing to select XY as the To Frame.

We are finished with the datum plane. Erase the
datum.
Zoom all to see the part in its new position.

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Chapter 2 page 29

Finish orienting your part by rotating it on the Y axis. To do this we will use the command
Move along direction. Use 0 for the distance value and 180 for the rotation value.

After rotating your part it should look like the following image.

You are only moving the Shape so make sure you dont window pick with the filter on All
.

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Dynamically rotate your view of the part so you can measure the distance between a point and
a point on the geometry (shape).
(shape)
There is a group of tools found on the Inquire toolbar that you can
use to measure distances, angles, etc... .

Pick Measure Distance

For this exercise you should select the option Distance > Geometry
to point as shown in the image.
image

Specifying the letter A for the name of the Variable.

For the Point enter the value 0,0,0.

Select the face indicated in

n the image. (Narrow face at the lip)

You will use the Z component of the distance in the next command. You can copy and paste
the number from the Measure Distance window or use the Variable A
A_Z that we created.

From the Tools pulldown, pick Variable Browser to see the format.

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Chapter 2 page 31

After storing the value of the distance on Z lets move the part along the -Z axis where you
can copy the value used before.

For the Direction

Right-click pick Z axis

For the Distance either type A_Z (We know this because we looked at the Variable Browser
on the previous page)
or Right-click >
Pick the Select Variable icon, then select the A_Z variable

Pick OK

Or

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As shown in the image below, paste the value from memory into the Distance
Distance box. The part
will then move that far along the -Z
axis.

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Chapter 2 page 33

In the next exercise you will scale the 3D model to compensate for shrinkage in the mold. A
scale of 0.6% is suggested. Scale the model using the command Scale entities that is found
in the Tools toolbar.
Select the Scale entities command. Select the geometry to be scaled.
Indicate that the scale is Uniform and then set the scale factor to 1.006.

Pick OK

Save your file.

You are now finished with the editing of this Part. Exit this section by using the
command Exit part.

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Chapter 2 page 35

Chapter 3

Creation of Core, Cavity and Parting Planes

Create a new Part named 03_Core_Cavity.

This new part will be used for core and cavity separation, and will be used in the construction
of the parting faces.

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After you have activated the new part, insert a component by using
the Insert Component command found on the right mouse menu as shown in the image.

Select 02_Part_Scale... as shown in the image.

Select the option Anchor component
omponent and locate it at
the coordinates 0,0,0.

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Chapter 3 page 37

After you insert the component perform a Merge so the object can be locally edited. Now the
surfaces belong to this part.
Select the Merge command found on the Shape toolbar. Select the object to be converted.
Another way to do this is to select the component, then select the Merge option found on the
right mouse button menu.

*****Note: In this application when

you Insert a Component you will
always Merge

Select the Attributes > Line menu and configure the thickness of the 3D lines that will be
created by the Parting Line command.
The color will have no affect here because the
color of Parting Lines is defined in the ZW3D
Configuration. The default is green.

Parting Lines will need to be created along the

exterior edges forming a closed loop. You will
also need to create Parting Lines around any
holes in your part.

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With the pick filter set to all, you will create the parting lines. Use the Parting line from
silhouettes command. Select the Z axis as the axis of extraction.
<middle-click> to accept all of the faces.
<middle-click> to finish the command.

Save
Blank the part and the exterior parting lines only by using the Blank command.
command With the pick
filter set to All, select the part and <Shift-click> the outer parting line.
U

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Chapter 3 page 39

Erase the leftover parting lines. We want to erase just the lines, and not the planes so be sure
to select the Parting Line filter and <right-click> pick all.

After erasing the unnecessary parting lines, select Unblank all entities.

Create a new parting line around the holes in your part by using the Parting lines from face
edges command.

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Using the command Parting lines from face edges indicate all the of the faces you wish to
calculate by picking the two large flat surfaces and the 5 vertical surfaces on the tab.

Flat surfaces

5 vertical surfaces

Select only the edges as shown in the image. If you get too many, <Ctrl
Ctrl-pick> to delete them.
pick
pick
Shift-pick

Again we should have a closed loop

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Chapter 3 page 41

Repeat the previous command by <middle-clicking> and create Parting lines on the edges
shown in the image. Pick the two faces and <shift-pick> the two edge loops.

Shift-pick
Again we should have two closed loops
To check for future problems in the Parting lines, select the Check for gaps in parting lines
command.

There should be no gaps or overlaps in order for the part to split in the next step.

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ZW3D has two commands to

o divide the model.

The command Separate into core/cavity regions is used for a fast separation
separation. You
simply select the surfaces to be separated and indicate the dividing
divi
axis.
You can define a layer for each of the parts.
Ex:
Z axis Layer for the entities belonging to the cavity
-Z axis Layer for the entities belonging to the core.

The command Divide faces a

at parting lines is only used when Parting lines exist.
Select all of the lines necessary for the division of the model.
model If you wish to separate
sepa
the object
into two Shapes, select the Separate Shape at Parting Line option. Otherwise the model will
be divided only on the surface and will n
not separate into two Shapes.

In this exercise we will use the command Divide faces at parting lines.
lines
Make sure the option to separate is checked. <right-click> pick all, <m
middle-click> twice

You now have two separate shapes. To temporarily

tempo
see the results blank shape or
Move Along a direction ( Z axis) select one of the shapes. When your done, Undo.

Save

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Chapter 3 page 43

Start the construction of a new Sketch using the Datum Plane XY. This sketch will serve
as the limit (border) for a parting plane. It will also be used to create the Mold Insert Block.

Your parting face boundary sketch does not have to be fully constrained because we dont
anticipate any changes being made, but just to get some practice we will constrain this sketch.
(Can you imagine an engineer saying he doesnt anticipate changes????) Changes to an
unconstrained sketch may cause unpredictable results.

All new sketches automatically have a point at 0,0 and an anchor constraint

Draw a rectangle
center, centered on the point. Use a width and height value of
552/2 or 276. (ZW3D will do the calculation in the text input window.)
The only thing left to fully constrain the sketch is to center the square on the point.

Select
mid point constraint found under the anchor icon.
Select two diagonal corners of the rectangle.
Select the point at (0,0)
An Alternate method:
There are predefined fully constrained sketches located on the Ready Sketch toolbar.
Use the Square.
Middle-click to place at (0,0)
Edit the width.

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After defining your Sketch we can exit the sketch by using the
option Exit Sketch found on the right mouse button menu or by
using the command on the toolbar.

In the next step, we will create a parting plane using some of the commands available in
ZW3D. But first, lets define a new color for the new faces that will be created.

To create the new face color select the command Default surface color.
color Define a color as
suggested in
n the image and apply this as the color.

3
2

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Chapter 3 page 45

With the Parting Face command ZW3D will automatically create parting surfaces. Select the
Sketch to which the parting faces will be limited. Next, <shift-pick> the exterior (outer) parting
lines. Lastly, <Middle-click> to skip the interior (inner) parting lines.

Envelope

Outer Parting line

Shift-pick

In the next step we will join all the surfaces that belong to the Parting plane.
Select the command Sew. This command recognizes all of the surfaces that belong to the
Feature parting plane. So we need to simply select one of the surface planes.

Notice the adjoining edges of

the parting plane are now sewn.

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To complete the parting faces you will need to create three inner shut off surfaces.
Select Create faces by inverting loops.
loops
( It is behind the previous parting face command. )
This will create missing faces on the areas shown in the image.
Face

Edge

Select one face and one of the edges. Repeat for the other shutoff. (NOTE: You
could <middle-click>
click> for the edge selection because there is only one
internal loop.
The last area to close off is the tab shown
s
right.
Erase the two parting line segments that you had to pick
separately in the previous step.
See the two dotted edges below.
Select Create faces at angles to surface and select the parting lines on the raised tab.
Shift-pick the parting lines on the tab.

Indicate
ndicate the value 10 for the size of the surfaces and 0 for the angle.

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Select Sew and pick once on the parting faces just created. Dont just pick OK.

From the orientation shown above you should be

looking at the back of the face (pink). Use Reverse
Direction if necessary. (probably not)

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Select Create faces at angles to surface again and shift-pick the other parting line that lies
on the flat surface.
Change the angle to -10 degrees

Select Sew and pick once on the parting faces just created. OK.

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Use the Combine Shape > Remove operation as suggested in the image.

Remove

Base

Result

Save your file

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Remember the sketch we created before our first set of parting faces?
We are now going to use that to create the mold block.
Select Extrude > Base

The Object called 03_Core_Cavity

03_Core_Cavity is a working part that contains 3 distinct parts of every
mold. The Core, Cavity and Parting Geometry. Construction of the three had to ocurr in the
same object but now they need to be separated into
into their own object files.

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Our next step will be to separate the different Parts.

Select the command Edit > Copy > Geometry to Part. Set the filter to Shape and start by
selecting everything related to the parting planes including the block......

.......Before finishing the command go back and change the filter to Curve, and select
everything related to parting lines.....
HINT: <Shift-pick> 5 times.

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Middle-click to repeat
epeat the command to create a Part for the core.

05_Reference_Core.
Give this Part the name 05_R

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Repeat the command again to create a Part for the cavity.

Name this Part 06_Reference_Cavity.

After creating the respective Parts,

Save

Exit part

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Once at the ZW3D objects level, select the Part 05_REFERENCE_CORE

05_REFERENCE_CORE and select Edit.

Insert the component 04_Parting

arting_Faces by using a
right mouse button menu. Select the Insert
Component option.
When you activate this option a new menu will pop up.
From this menu you can select a part to insert into the
active Part. You can preview the parts
p
before insertion
by selecting the Preview - Graphics option. This way
you can be sure you have chosen the right part before
you insert it.
Select the object 04_Parting_F
_Faces as the
component to be inserted.
Select the Anchor component option
Locate it at the origin point (0,0,0
0,0,0) as shown in the
example.
Pick OK.

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Be sure to Merge the component after inserting it.

Or right-click Merge

Remember, our component is now a shape.

Activate the Mold toolbar and select the Trim plates to core/cavity region command icon.
Select the block. Select the core. On the menu that pops up, select the Flip option.
<window-pick> all of the surfaces of the parting plane (4). For the copy option select Neither.

You now have a closed solid shape.

Save

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When you have finished the command your object should be identical to the image below.

At the ZW3D Objects Level, select the Part 06_Reference_Cavity to be edited. Now we will
apply the same techniques that were used to define the reference core.

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Insert the Parting Faces component as shown below.

Select Merge. (RMB)

Trim the plates as you just did in the

Reference Core.

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The next part of the exercise will demonstrate how to associate parts together so if a change is
made to one it is propogated automatically to the others.
Select the 04_Parting_Faces
aces part to edit.

Blank the block.

Erase the six surfaces shown in yellow in the image (6).

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Chapter 3 page 59

Once you have erased the surfaces on the corners of the parting plane you can rebuild them
using the Drive curve loft command.
This next step will create a single face between the edges. Dont forget to activate the Smooth
option so the connection will be tangent to the ajoining faces.
toolbar

Its necessary to extend the surfaces so they will exceed the limits of your block. To do that we
use the surface command, Extend, available on the Free Form toolbar as shown in the
image below. Use an extension value of 10.

Repeat this process to extend the other surface.

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Select the Unblank command and apply Fillets with a radius of 30mm
mm on the edges shown
in the image.

We need a method
thod for automatically updating the Reference_Core and Reference_Cavity to
reflect these and any changes made to the Parting Faces object.
The next step will update
e all the parts that are associated to the parting planes.

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Link Manager
Select the ZW3D objects Link Manager found on the Tools menu.
Select Insert and select the objects to be updated. In this case, select the parts
05_Reference_Core and 06_Reference_Cavity.

Select Select All.

Check the option Auto Regen to turn it on.

If the user sets up the link manager to do an automatic regen of the Reference parts, each
time the 04_Parting_Faces part gets regened, so do the Reference_Core and
Reference_Cavity.
Select Dismiss

You can now run the Regen

command. Watch the message window and you will see
that the two reference parts are also regening.

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The reference core and reference

reference cavity are now updated according
ing to the modifications
that we created on the parting plane.

Create
reate a new object with the name shown below.. It will be used as a separator.
This separator is nothing more than a ZW3D object with a visually unique name.
name This helps us
visualize and separate the different steps of the project in the Objects window.
window
We suggest you follow this type of naming scheme. Since
ince each part is based on the previous
one, using numbers will help to organize your models in the object list.

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The next step will create a new Part/ Assembly object. This is where youre going to set up
your mold.
Create a new Part/Assembly object and name it 08_Mold_Assembly.

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Insert the component 09_Core

ore_Group at the 0,0,0 point.
This is a new part object so just type the name as
shown.

This component doesnt exist so ZW3D will create and

activate it automatically for editi
editing.

he user knows which file is active

active. The name appears
The
on the ZW3D title bar.
ZW3D automatically created, inserted and activated a
new component

In this new object we will create all of the core group

reference information.

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The core should be the first object you create in this group. To do that, Insert a new
component and name it 11_CORE. Anchor and Position at (0,0,0).
Once more the system creates a component and automatically activates it for editing because
it doesnt yet exist in this project.

Notice that activating the part changed the name of the new object in the title bar and inserted
it into the core group.

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After creating the core object, insert

inser the component 05_Reference_Core
ore. Anchor and
Position as before.

Merge it using the same operations as before.

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Use the command Exit part to position it in the 08_MOLD_ASSEMBLY object.

Use the same insert technique again to create the cavity group.
Insert the component 10_CAVITY_GROUP into the active object 08_MOLD_ASSEMBLY.
We will also be creating and activating a new component here. The following is an outline of
the steps for the cavity side. They are identical to what we just did on the core side.
Insert a new component called: 12_Cavity

anchor and position it at (0,0,0)

Insert the 06_Reference_Cavity anchor and position it at 0,0,0 and Merge it.

Now we have an assembly which contains 2 sub-assemblies

08_Mold_Assembly

09_Core_Group

11_Core

05_Reference_Core

10_Cavity_Group

12_Cavity

06_Reference_Cavity

The core and cavity groups will have more components added like inserts and slides but this
should give you a better feel for what we have done and where we are going.

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Use the command Exit part to position the 08_MOLD_ASSEMBLY object.

Here you can see the assembly o

of your mold divided by groups.
See the History to verify.

At the ZW3D Objects level you will see that new objects were added to the file.

Again, notice the

naming structure. In
reality we suggest
separating the groups a
little more than we have
done here. You may
want to use
100_Core_Group and
200_Cavity_Group and
use numbers in those
ranges.

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Chapter 3 page 69

Chapter 4

Creating your first insert

Select the name 08_Mold_Assembly from the Object list to edit.

Select the ZW3D Assembly Manager, using the right mouse button menu...

********NOTE: At first glance, one may think we are done. We now have what looks like the
core and cavity in an assembly. However, there are more parts to create for this mold.
There are a couple of inserts and slides required as well as the geometry used to subtract
material from the core and cavity to accomodate the inserts and slides.
With the Assembly Manager, you can hide, erase, or select a part to edit. You can also double
click a part for editing by setting the filter selection to All or Component options.
For this exercise it doesnt matter so select an edit method for the component
09_CORE_GROUP.

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After activating the core group

group, select the option Show target so that only the objects in this
group, in this case the core,, will be visible.
visible

Insert a new component in the core that does not contain any geometry. You will be
creating one of the inserts.

Insert a component and name it 13_Core_Insert_01. Anchor and locate it at 0,0,0.

Since this component does not yet exist, the system will create and activate it automatically for
editing.

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If you select the Show Target option again you will see the only things that exist are the three
default datum planes. You may have to pick this twice. The icon will toggle between Show All
and Show Target.

Since this object was created as an empty part, you must insert the component
05_Reference_Core.

As in previous steps, anchor and position at the 0,0,0 point.

Merge

When you are finished the construction of this insert, the above shape will be trimmed away
leaving you with the insert and the tool used to remove material in the core.

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Now we will add some geometry to 13_Core_Insert_01. Lets create

e an Extrude. The
sketch should be on the XY datum plane.

*******Hint:
Hint: Any time you are creating a sketch on the XY datum plane,
<middle-click> twice.

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Create a two point rectangle and dimension it from the point located at (0,0).
For this Sketch use the dimensions shown in the image below.

Exit Sketch by using the right mouse button menu.

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The start value of your extrusion will be the point shown in the image below and an end value
of 50.

our object should now look like this.

After creating the extrusion, select the Shade button. Your
Save

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Chapter 4 page 75

Hide the core reference, by using the Blank Entities command icon.

Create an extruded boss on the new component.

Add an extrusion.
image.

Your sketch should be located on the highlighted face shown in the

Reference curves should automatically be created if you set the option in the configuration file.
If not, use the following.

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Draw a 2 point rectangle on the reference plane with the dimensions shown below.

Exit Sketch and complete the extrusion form as shown. Give it a start value of 0 and an
end point at the point shown in the image.

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Unblank so the core reference will be visible.

Create a boolean operation Shape toolbar > Combine Shape between the two entities by
using the Trim Shapes command.
In this command, the Reference Core will be the object for the base and the object for
trimming will be the previously created solid.
Be sure to select the options Flip side to keep and Keep trimming shapes.

2
1

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When you have completed the command it should look like the image shown.
shown We now have
the insert and the subtraction
subtraction tool
tool.

As shown in the image above,, you should Blank the actual insert and create a clearance gap
on the subtraction tool that will be used on the core insert.
Use the command Face Offset
Offset. Select the face indicated in
n the image and give it a value of
0.5.

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Chapter 4 page 79

Copy Insert to the Core

After creating the clearance gap, export the geometry. Select the option Edit > Copy >
Geometry to Part. Select the shape, and indicate the part for the destination (11_CORE).

Swap entity visibility. This will hide the insert

subtraction tool and make the actual insert visible.

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Link Manager
You need to associate the insert with the core so that anytime the insert is altered the core
will be updated as well.
Activate the ZW3D objects Link Manager and insert the object 11_CORE
11_CORE into the
regeneration list.

Regen will regenerate the history of the active part as well as 11_core.
The part 11_Core is created from the 13_core_insert_01 part with the copy geometry to part
command. This does not create a history operation in the 13_Core_insert_01 part, but does
create a history operation in the 11_Core part. This means that if the 13_Core_insert_01 part
gets changed, the user has to manua
manually go into the 11_core part and perform a regen so that
the latest geometry gets read in to the 11_core.. If the user sets up the link manager to do an
automatic regen of the 11_Core part, each time the 13_Core_Insert_01 gets regened, so
does the 11_Core.
Reactivate Parent Object so you are in the 09_Core_Group.

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Set the filter to component and <double-click> the object 11_Core to activate it.

Use Combine Shapes > Remove, where the object base is the core and the subtraction tool
is the shape to be removed.

Base
Remove

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th case will be the

Select the option Show target to show only the active object, which, in this
core.

one that belong to the

If you wish to see the objects that are on the next level, and not just the ones
this assembly, use the command Show More found on the menu View > Show Scope >
Show More.

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Chapter 4 page 83

to open the ZW3D objects editor.

Select the 13_Core_Insert_01, and click Edit.

Right click on Trim1 as shown below and select the option Rollback
from the History Manager.

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Add Fillets each with a radius of 1

Window pick the edges shown in the image.

Complete the history replay by clicking the Replay all operations button.
button

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To change the core according to the modification on the core insert, Edit the 11_Core and
select the Regen command.

When you analyze your core object you can verify that its updated according to the edits you
just made to the core insert.

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Optionally, lets use the techniques previously employed in the construction

construct
of the first core
insert to construct the
he second core insert. Name it 14_Core_Insert_02
_02.

Dont forget, that when you create the second core insert, the core group
group 09_Core_Group
should be active.

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Chapter 4 page 87

Chapter 5

Creating your second insert

For the next step of this exercise lets create another insert in the core. The core group
should be activated first.

Insert a new object component and name it 15_Jiggle_Pin_01. Anchor and position it at
the coordinate 0,0,0.

As on previous exercises, we have to insert the Reference core in the active part.

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Merge the core reference component.

component

insert, you must first create an Extrusion on the XY datum plane

To create the shape of the insert

Create a 2 point rectangle as shown and dimension it to 0,0.

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Exit the Sketch and complete the extrusion with the values shown in the image.

*******Note: Orient the part as shown here before adding draft.

Use the Blank command to hide the core reference.

Now that we have created the geometry for the head of your insert, we need to add draft
angles on the lateral faces.
Use the command Draft and select the filter option Edge. Select the edges as suggested in
the image. For the reference plane, select the bottom face of the insert as indicated in the
image. Also indicate the value of the angle, in this case -1. Select Bottom for the Draft
side option.

*******NOTE: Because the angle is so small, one way to verify that you indeed do have the
draft applied is to toggle back and forth with the Undo and Redo commands.

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Based on the information shown in the image repeat the same

ame command on the indicated face
and apply a -6 degree draft angle. Use the bottom face as the reference plane.

Draft again and apply a -4 degree angle to the bottom face as suggested in the image.

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Chapter 5 page 91

Create a Sketch on the bottom face of the insert.

Create the references suggested in the image and create a circle with the dimensions shown.

Right Mouse click >

Chapter 5 page 92

Exit Sketch

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Create an Extruded Boss. The

he start value is 0, and the end value is 100.

shown
Fillet with a radii of 3 as shown.

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Chapter 5 page 93

Unblank to make the core reference visible.

Erase the bottom face with the pick filter set to face.

Create a trim operation between two entities by using the Trim Shapes command.

In this command the object for the base will be the core reference
and the trimming object is the solid created previously.
The options Flip side to keep, Keep trimming shapes and Cap Trimmed
regions should be selected.

Result

Chapter 5 page 94

Subtraction
tool

Insert

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Copy Insert to the Core

C

Blank to hide the insert.

Z3

You now have the tool used

d to subtract material from the core.

Select the command Edit > Copy > Geometry to Part to export this to the core.
core Select the
solid and indicate the destination part (11_CORE).

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Chapter 5 page 95

Link Manager
You can change the workzone by clicking Swap entity visibility. This will hide the
subtraction tool and make the insert visible.

Now, we just need to associate the files of the insert and the core. This way if any change is
made on the insert the core will be updated as well. Remember, this needs to be done when
you use the Copy Geometry to Part command.
U

Select the ZW3D objects Link Manager from the Tools Pulldown and insert the object
11_CORE into the regeneration list.

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Exit part until you are in the 09_Core_Group object.

Set the filter to component and <double-click> the object 11_CORE

11_CORE to activate it for edit.

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You need to do a Combine Shapes > Remove where the base shape is the core and the
subtraction tool is the shape to be removed.

Show Target
Your part should look like this.

As an optional exercise, create another insert named 16_JIGGLE_PIN_02.

After the final construction of the two inserts your core should look like this.

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Chapter 6

How to cr
create Sliders

To create slides that belongs to the core group we should edit the 09_CORE_GROUP.
09_CORE_GROUP

Create a new object anchored and positioned on the coordinate 0,0,0

0,0,0.
Name it 17_SLIDER_01
We have to insert the reference cavity into the active part 17_SLIDER_01
17_SLIDER_01.
U

Merge the component to make a shape.

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Chapter 6 page 99

Create an Extrusion. The sketch should be on the XY datum plane.

Create a shape just like the one shown in the image. Dimension it to the coordinate 0,0.

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Exit Sketch and

d continue the extrusion with the values indicated in the image.

Use the Trim Shape command to create a trim operation between the 2 entities.

The base is the reference cavity

cavity and the solid previously
created is the trim object.
Verify that the three optional inputs shown at the right are
checked.

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Chapter 6 page 101

Copy Slider to the Cavity

Your object should look like the image below.

Blank to hide the front of the slide.

Lets export into the cavity the subtraction tool for your
slide. Select the command Edit > Copy > Geometry to
Part. Select the solid. Indicate the destination for the
export 12_Cavity.

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Swap Visibility and lets add some geometry to the slide.

slide You need to create a reference point.
point
Create an extension for your slide.
Open the Wireframe menu and select the Point command.
Select the options Critical + Center of Curvature from the right mouse button menu as shown
in the image. Select the edge on which to locate your point.

Insert Sketch as shown in the image.

image

Up until now we were not

concerned where the origin
of a sketch was when
sketching on a face.
Now we want the origin to be
projected from the point we
just inserted.
Use the Origin option and
pick the point entity we
inserted in the last step.
Pick the line indicated by the
arrow for the UP direction.

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Chapter 6 page 103

Draw the sketch shown below.

Exit Sketch

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Extrude using the Add option, with a start value of 0 and an end value of 60.
If your sketch was drawn correctly this seam will disappear.

Create a draft angle for your slide.

xtrusion using the Remove option. <Middle
Middle-click> to create a new
Youll need to create an Extrusion
sketch. Select the Up option on the commands dialog menu and select the edge indicated
below. The sketch should be on the highlighted face shown in the image.

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Chapter 6 page 105

Create a reference curve on the three edges in the upper left of the part.
(one horizontal and two vertical)
Create a line as shown. Use the suggested dimensions.

Use the command Trace Profile to create a curve. Select just the three entities that you want
to see.

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Link Manager
Exit your sketch. Complete an extrude using the remove option with a start value of
0. End it on the point shown in the image.

Use the Link Manager again to force the 12_Cavity to automatically regen any time the slide
is regened.
Exit part to go to the 09_Core_Group
09_Core_Group object.

Here we can analyze all the objects that belong to this group.

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Chapter 6 page 107

Once you are in the main assembly of the mold, set the filter to component and <doubleclick> the object 10_CAVITY_GROUP to activate it.
<double-click> on the object 12_CAVITY to activate it.
Combine Shapes > Remove operation where the base shape is the cavity and the slide tool
is the shape to be removed.

As your final (optional) exercise, create a second slide for

the mold.

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Appendix A

2D Drawing Layout
L

In this new chapter we will create

crea 2D drawings based on the 3D objects previously created.
Create a NEW - Drawing Sheet object.
Select the drawing sheet template.
template You can accept the automatically-suggested
suggested name.

These sheets can be configured

ed by the user. The Template file that holds
hold all of the definitions
is located in the .\User-14.00\resource
resource directory. Starting with version 13 there are two
template files. Templates_IN.Z3
Templates_IN. and Templates_MM.Z3.. Depending on how you answered
the question when you entered ZW3D the first time, you are using either the inch or metric
template file. See the Files tab of the ZW3D Configuration.

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Appendix A page 109

Before beginning to draw, look at the ZW3D configuration.

See the Color tab and Display tab. Dont change anything yet. Review the
color settings for anything related to 2D geometry. The display tab defines
global settings for line thickness.
Now cancel.
Select the Attributes pulldown menu.
The first option we will look at on this menu is a line-type configuration.

Here the user can override the attributes set in the configuration of new lines
that will be created.
This will be in affect for any sheet created during the currect session.

If you wish to alter any existing entities select the Attributes option from the
middle or right mouse button menu. This option will activate the same menu as
shown above, but it will only affect the selected entities.
You can also keep these settings for later use by Saving a Bundle. See
the On-line HELP or try it yourself.

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Another
ther option available on the Attributes menu allows for
the configuration of the dimensions.
dimensions Here the user can
intuitively configure the aspect of dimensions to apply to the
drawing.

Other menus are used to define the text style and the type of
Hatch pattern that should be applied to sections.

These configurations can be done in the Template_IN.ZW3D

and Templates_MM.ZW3D files
file as opposed to a single
drawing sheet, and since every new project is based on the
template the software will assume the new configurations
that were previously defined.

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Appendix A page 111

The last option available on this menu changes the properties of the 2D views that are created
from the 3D objects.
Here the user can define ways of representing the views: hidden line or shaded, scales,
aspects of lines, layers etc.

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As a first exercise select the command

shown in the image. This command lets
you create 3 or 4 views of the selected
model, redefine the parameterss
configured by default, and indicate the
type of projection intendeda
a 1 degree angle or a 3 degree angle.
Select 11_CORE as the object to be used in the 2D views. Click OK or <middle-click> to
finish.
Your first drawing should look like this.

After creating the views its possible to change their position on the drawing.
drawing Just select the
desired views and right mouse click Move. Select the starting point and the destination point.
You can also use this menu to alter the attributes of the selected views. Select the isometric
view and change the hidden lines attribute from dashed to Ignore.

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Appendix A page 113

For the next exercise youre going to create different types of sections. You can choose
between simple sections showing the cross section only and sections showing a hidden line
view of the entire part with the sectioned volume removed.
In the Section command indicate if you want to create a simple Sect Curves or a
Trimmed Part section type.

Create the detail views. In ZW3D there are three types of details.

Create a circular detail from one of the sections shown in the previous image. Give this a
scale of 4.

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mensions using the Right Mouse B

Button menu.
Add dimensions
So the final result of your project should look like the image above with dimensions.
dimensions

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Appendix A page 115

Appendix B

Mold Base Creation

The first time you pick this icon you will get the old Mold Base menu. This has been
discontinued but is here only temporarily while we transition to the new Mold Expert software
from Antares.

Save your file and click on the Applications pulldown menu.

Click on Install Mold Expert

The messages above will be displayed in the message window and you will have to restart
ZW3D.
Start ZW3D and open a file.
Click on the User pulldown and select MoldExpert

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Click on the Mold Base icon shown above.

There are two versions. Basic gives you the same

functionality that we had in the old software at no
additional cost. You will probably notice that some
icons on your screen are hazed out. Those
commands are included in the Advanced version.

Click on the Configuration icon to obtain a license

for the Advanced version.

MoldExpert has its own HELP.

The following is an outline of the steps to get started:

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Appendix B page 117

Open a new part object for your MoldBase Assembly.

Insert Component Core 11_Core
Insert Component Cavity 12_Cavity
Component Merge ... pick both components --- --------

These need to be shapes at this point
Insert the MoldBase

The Frame will typically be the XY datum.

Either type XY or pick the plane from the graphics area.

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The bounding box option allows you to pick geometry which will be used to automatically
select the appropriate mold base size. You can think of it as an envelope.

Select the button highlighted above

You will have 3 options for defining the bounding box. You can pick the core and cavity
shapes, select two diagonal critical points, or enter values.
The Extra X and Y sizes are to give you space around the core and cavity for cooling lines,
etc.

You can accept this size or continue to edit the sizes that were selected.
Select OK

The moldbase will be inserted.

The plates are shapes and the other hardware are components. It is done this way so you
can work on the plates.

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Appendix B page 119

Typically the next step is to subtract material from the Plates to accomodate the core and
cavity.

Extrude a Base Shape using the Right-click Insert Curve List option.
<Shift-pick> the entities that make up the top edge of the cavity.
U

Start at 0
End at <Right-click>

Combine shape remove from the 2 plates.

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Before we insert some screws lets look at the configuration tool.

We are going to insert 4 identical screws so check the option, Retain last used values
While we have this menu open lets look at the Catalogs tab.

If you dont have access to all the moldbases listed you can subtract some from the visible list.
You can also select the catalog that you use the most. If it is the only one you use, check the
box.

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Appendix B page 121

Pick the Standard Elements icon and we are going to insert 4 socket head cap
screws to hold the cavity to the top plate.

The point will be the critical center of the four radii on the cavity.
Repeat this for the other three.

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