Course Duration: 40 hour
Tuition: $2,500 USD
Overview: The course includes Design Engine’s Die Cast Class, Plastics Class, and Forging Class into this forty hour one week intensive. Refer to those specific web pages for precise course material. This class is not for Pro/Engineer beginners. Training material for this one week design intensive has been designed to provide a working knowledge of both the molding and forming industry and includes more than half of the hours utilizing modeling techniques in Pro/Engineer. This class does not cover the actual writing of CNC code for numeric controls or sheet metal as those are separate Design Engine classes.
Prerequisites: Significant knowledge of Pro/Engineer or another parametric 3D CAD modeler.
Die Cast Part Design
Die Casting Short List Of Topics:
- The process, die cast molds, tooling, processing factors, nominal walls, radii & draft angles, ribs, weldlines, stress, cooling metals, bosses, and undercuts
- Snap fit, FEA, design recommendations, and overview of flow mold analysis software
Short List Of Die Cast Discussions:
- Discuss cooling time as related to thick sections of aluminum. Discuss internal voids and fundamentals of other problems that occur from improper piece part design
- Discuss using parametric modelers in general and discuss examples where using variables with a parametric modeler can prevent problems in the future complete with in class examples
Pro/Engineer Specific:
- Discuss Draft in it’s many forms complete with examples of Split, Draft, etc
- Learn to use surfacing and discuss it’s usefulness with die cast part design
- Learn to use top down design with examples in Pro/Engineer
- Adding Draft to parts that currently have no Draft
There is a great deal of HTML course material students take back with them from this workshop. For complete list of the Die Cast Part Design course material, see the Design Engine Die Cast Class page.
Click To View Die Cast Part Design Images:
Plastic Part Design
Plastic Part Design Short List Of Topics:
- Product development and prototype
- Mold Filling, gating and weld lines
- Mechanical behavior of polymers
- Shrinkage, warpage and part ejection
Plastics Discussions:
- Discuss basic design elements in plastic part design. Holes, ribs, thin wall features, bosses, nominal walls, and fill
- Discuss general rules for hollow boss design and discuss best practices. Learn about thin steel or thin blade areas and discuss ways to avoid these scenarios
- Designing undercuts and discuss advantages and disadvantages as relative to costs
- General disclaimers on drawings such as “brake all sharp corners”. In this exercise participants will add Draft and prepare any number of parts for the plastic injection molding process
Pro/Engineer Specific:
- Light surfacing and its use with plastic part design
- Discuss top down design with examples
- Adding Draft to parts that currently have no Draft
- Discuss making parts moldable that others created
- Tips tricks and techniques for starting and completing plastic parts using Pro/Engineer
For complete list of the Plastic Part Design course material, see the Design Engine Plastics Class page.
Click To View Plastic Part Design Images:
Forging Part Design
Forging Part Design Short List Of Topics:
- Overview of the forging process complete with tooling and outside machining operations
- Forging process by which metal is heated and shaped by plastic deformation by suitably applying compressive force
- Discuss the progression of a forging process
- Open Die Drop hammer forging
Forging Discussions:
- Discuss alloys with respect forging
- Compare cold forging to hot forging and warm forging
- In detail steps of the forging process
- Discuss strengths and weakness of outsourcing
Forging Short List Of Tutorials:
- Motorcycle brake Lever
- Pivot bracket
- Harley rod
- Motorcycle kickstand
For complete list of the Forging Part Design course material, see the Design Engine Forging Class page.
Click To View Forging Part Design Images:
“Design for Manufacturing”, “Design for Manufacturability”, ”Die Cast Design”, “Design for Die Casting”, “Plastic Part Design”, “Plastics Design”, ”Design For Forging”, “Forging Part Design”
