CAE Technology: A Tool for Mold Design
The mold industry plays a crucial role in the national economy, serving as a fundamental sector that supports various industries such as automobiles, electronics, instrumentation, aviation, and home appliances. Approximately 60% to 80% of components in these sectors rely on molds. The design and manufacturing standards of molds directly influence product quality and production efficiency. Over the years, mold design technology has evolved significantly, with the rapid development of CAD/CAM/CAE systems. Among these, CAE (Computer-Aided Engineering) has become widely adopted and is now an essential tool in modern mold design.
Several commercial CAE software packages are commonly used in the industry, including Dynaform, Deform, Autoform, Superform, Pam-stamp, Fastform, Moldflow, Polyflow, and more. These tools are primarily used for virtual tryouts of forming processes and play a vital role in guiding mold design. They help engineers simulate and analyze complex manufacturing scenarios, reducing the need for physical prototypes and saving both time and resources.
In extrusion die design, CAE simulation technologies are extensively applied. For instance, Deform is a widely used finite element-based simulation system designed for metal forming processes. It allows engineers to simulate and optimize the entire forming process virtually, which helps in designing molds more efficiently. By analyzing stress distribution, deformation, and material behavior, designers can make informed decisions that improve the performance of the final product while reducing costs and development cycles.
Figures 1, 2, and 3 illustrate the results of simulations for different extrusion processes—positive extrusion, compound extrusion, and back extrusion. These visualizations help in identifying potential issues early in the design phase, allowing for necessary adjustments before actual production begins.
In sheet metal forming, Dynaform is a popular choice due to its user-friendly interface and powerful features. It offers comprehensive CAD, pre-processing, analysis, and post-processing functions, making it ideal for stamping simulations. By using CAE technology to simulate the stamping process, companies can significantly reduce the cost of trial molds and enhance the overall quality of the mold design.
Figure 4 shows a schematic of an aircraft part mold, while Figure 5 highlights the initial stamping defects. Through CAE simulation, it was identified that certain areas of the material were under-stretched, while others were excessively thinned. By modifying the die structure and adjusting the drawbeads, the material flow could be balanced, leading to a significant improvement in the final product's quality. Figures 6 and 7 show the improved results after the design changes.
In injection mold design, Moldflow’s MPI (Moldflow Plastics Insight) is one of the most commonly used tools. It simulates the entire injection molding process, helping to optimize part design, mold layout, and injection parameters. It also supports advanced techniques like gas-assisted injection molding, providing valuable insights into flow behavior and pressure control.
Figures 8 through 11 demonstrate how CAE technology is applied in optimizing plastic parts and molds. Initially, the product showed a Z-direction deformation of 18.8 mm. After design modifications, this was reduced to 7.1 mm, making the result acceptable for the user. These improvements highlight the importance of CAE in achieving better product performance and reducing manufacturing risks.
Looking ahead, CAE technology is expected to become even more integrated into mold design and development. However, challenges remain, such as the lack of skilled personnel and resistance to adopting new technologies in some enterprises. While CAE software is powerful, it requires not only technical skills but also a strong foundation in theoretical knowledge and practical experience.
As CAE simulation technology continues to evolve, its integration with mold design will lead to more efficient and accurate design processes. By simulating molds under various conditions, designers can gain deeper insights into the forming process, ultimately improving design efficiency, reducing risks, and accelerating the development of high-quality molds.
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