Wednesday, August 21, 2013

SOLIDWORKS TECH TIP: Troubleshooting mold "Tooling Split" failure

When working with the Mold Tools functionality in SolidWorks, it's important to make clean, "water tight" surfaces for the "Tooling Split" tool to work properly.

There are some other considerations to think about as well. If you ever get the error: "Rebuild Errors – The parting surface must be larger than the boundary of the sketch", there can actually be several reasons you're getting this message. The following are the most common items to check for to correct the issue.
  1. Confirm the Core/Cavity block SKETCH is completely inside/SMALLER than the PARTING SURFACE border. This holds true unless you are trying to use the automatic "Interlock Surface" option. In that case, the Core/Cavity block SKETCH should be completely outside/LARGER than the PARTING SURFACE border.

  2. If you have MULTIPLE surfaces in the CORE and/or CAVITY and/or PARTING SURFACE folders, make sure you can KNIT the surfaces (in their respective folders) into one surface.
  3. After knitting into one surface, examine the surfaces. Make sure there are NO internal blue edges (core and cavity surfaces). The parting surface should have two blue edges. There will be an inside and outside blue edge, but it should not have any crossing blue edges. Internal/crossing blue edges indicate a gap in the surface. If you knit the surfaces into one surface body, use the TOOLS/CHECK/SELECTED ITEMS option. There should only be one OPEN SURFACE found. If there is more than one, look for the blue edges.
    Note: Even if it indicates only one open surface, that surface still may have a gap in it. Picture a circular band: Even though there is an inside and outside edge, it will list as one open surface. This is fine; however, if there is a gap/missing surface that crosses the band, the surface would basically form a "C".

    This would still list as one open surface but would NOT work for a parting surface. If you see any unwanted blue edges, double check your "Knit Surface" features and see if there are GAP ranges displayed. If so, check the gap range boxes and Accept. See if the gaps (blue edges) are resolved. The surfaces need to be one continuous surface with only the external edge blue.
    1. If so, confirm you created a copy and place one in BOTH the CORE and CAVITY folders.
    2. If manually created, then you would have needed to use the SHUTOFF SURFACE/ALL NO FILL option. Make sure you built your shutoff surface to this line. If not, you need to modify your surface (or shutoff line) so it falls on the ALL NO FILL line. This is where the mold halves are trying to separate and add the shutoffs. If the Shutoff Surface and Shut Off lines are in different locations, it will fail.
By checking off the above list, you should be able to resolve the majority of your "Tooling Split" issues.

Happy Modeling!

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