Injection Mold Project

DO NOT do a mold of the same part that I do in the videos!

USE YOUR OWN original design.

As a minimum, you will use NX to set up a manufacturing assembly and create the following operations:

  • Use G59 for all operations

Note: Your mold itself does not have to have all of these features. If you do not want (for example) any engraved detail on you mold you can simply program those features on the back side of your block.

CONSTRAINTS:

  • 1) Blank dimensions are 1.00 x 2.00 x [4.00 max long] – Non-negotiable.
  • 2) Material is 6061-T6511 aluminum bar.
  • 3) Tools are limited to those on this spreadsheet: Tool Number Assignments (Links to an external site.)
  • 4) The mold MUST NOT BE the stepped-cup shape I do in the videos.  Come up with something more original.
  • 5) Use the Kurt D688 Vise and 1.375 Parallels for setup.
  • 6) Work offset origin is corner of vise (top left corner of fixed jaw).

HINTS:

  • Keep it simple.  Small details that require tools smaller than .125 should be avoided.
  • Keep the wall thickness under .125.  Shoot for .05 to .08.
  • Properly document all operations.
  • Post-process individual operations as their own program.  This is not typically done in industry, but it is best for our purposes.
  • The sprue must be located as shown on the injection mold examples slides.  Your design must fit within the injection molder we have on campus.
  • Keep in mind that geometry (such as text) will be reversed in the mold so it will be correct on the part.
  •  Part A: Create Mold Model
  •  Part B: Create Mfg Assembly
  •  Part C: Create Geometry
  •  Part D: Face Milling
    • Use T01, Face Mill 2.0 Diameter
      Workaround: Under MILL PLANAR, use FLOOR FACING WITHOUT WALL
    • Use workpiece geometry as usual, under MAIN tab, use SPECIFY CUT FLOOR AREA and specify the top surface of the part.
  •  Part E: Postprocessing and Documenting
    • Use the postprocessor that is on this page: Common Setup Files
    • You will need to extract the files. Keep all 3 files together in the same directory.
  •  Part F: Cavity Milling
    • Default tool: T01, End Mill, 0.500 Diameter
    • Use Main->Containment->”Use 3D” or “Use Level Based”
    • Note: You may need to use REST milling to clean up with a smaller tool. Use the same containment method with the smaller tool.
  •  Part G: Engraving (see workaround)
    • Use T05
    • Important Workaround:Use this operation:Under “MILL CONTOUR” use “CURVE DRIVE”
      On MAIN, choose DRIVE METHOD: Curve/Point.Click the wrench to select the curves. If you have multiple curves, hit mousewheel or “add new set” after each one is selected.Under NON-CUTTING MOVES, change Engage type to “PLUNGE” and retract to “SAME AS ENGAGE”On the GEOMETRY tab, add a negative part stock (such as -.020).  You may get an error message, ignore it (say “no”).

What to turn in:

Note: Failure to turn in the required files in the proper format will result in a loss of credit.

1) A PDF of completed documentation sheets for each operation.  You may submit each PDF separately, or as a single file (preferred).  DO NOT ZIP your PDF file(s). You should have documents for the following:

  • Face Milling
  • Cavity Milling
  • Engraving
  • Sprue
  • Deburring
  • Spot Drilling
  • Peck Drilling

2) A ZIP file (Compressed folder) of your COMPLETE, FINISHED ASSEMBLY.

  • Upload all of your PRT files for this project here.
  • INCLUDE setup files such as vise and parallels.

3) A ZIP file (compressed folder) containing a TXT (CNC) file of EACH operation.