CAE Technology: A Tool for Mold Design

The mold industry plays a crucial role in the national economy, serving as a foundational sector across various industries such as automotive, electronics, instrumentation, aerospace, and home appliances. Approximately 60% to 80% of components in these sectors rely on molds for their production. The quality and efficiency of products are directly influenced by the design and manufacturing standards of molds. Over time, mold design technology has evolved significantly, especially with the rapid development of CAD/CAM/CAE technologies. Among these, CAE (Computer-Aided Engineering) has gained widespread adoption and continues to grow in importance. Several commercial CAE software tools have emerged to support mold design, including Dynaform, Deform, Autoform, Superform, Pam-stamp, Fastform, Moldflow, and Polyflow. These tools are primarily used for virtual tryouts of forming processes and provide essential guidance in the mold design field. They allow engineers to simulate and analyze complex manufacturing scenarios before physical prototypes are created, thereby reducing costs and improving design accuracy. In the context of extrusion die and process design, Deform is often used for simulating volumetric forming processes. This finite element-based simulation system helps analyze metal forming processes across various industries. By replicating the entire manufacturing process on a computer, engineers can optimize mold design, reduce the need for costly physical trials, and enhance overall efficiency. Virtual testing allows for the analysis of die stress, elastic deformation, and damage, which is critical for ensuring product quality and performance. Figures 1 through 3 illustrate the results of simulations for different extrusion processes—positive extrusion, positive-negative compound extrusion, and back extrusion. These visualizations help identify potential issues and guide improvements in both the process and mold design. Through the application of CAE technology, manufacturers can achieve better outcomes and reduce the time required for product development. In sheet metal forming, Dynaform is widely utilized due to its user-friendly interface and advanced automation features. It offers comprehensive CAD, pre-processing, analysis, and post-processing capabilities, making it an ideal choice for stamping simulations. By using CAE to simulate the stamping process, companies can significantly cut down on trial mold costs and improve the quality of mold design. Figure 4 shows a schematic of an aircraft part mold, while Figure 5 highlights stamping defects in the initial design. Through CAE simulation, engineers identified areas where material flow was uneven, leading to thinning and other quality issues. By modifying the mold structure—such as adjusting drawbeads—the material flow could be balanced, resulting in improved part quality. Figures 6 and 7 demonstrate the final optimized results, showing a more uniform thinning rate and better forming limits. In injection mold design, Moldflow’s MPI (Moldflow Plastics Insight) is one of the most commonly used CAE tools. It enables the simulation of the entire injection molding process, from plastic flow to filling and holding pressure. This software also supports gate optimization, flow channel balancing, and even gas-assisted injection molding simulations, helping to refine both the mold and the manufacturing process. Figures 8 through 11 illustrate how CAE technology aids in optimizing product design and mold structure. Initially, a product showed significant deformation in the Z-direction, but after adjustments in the process and mold design, the deformation was reduced. Finally, a redesign of the product led to a much more acceptable level of deformation. These examples highlight the value of CAE in identifying and solving real-world manufacturing challenges. Looking ahead, CAE technology is expected to become an indispensable tool in mold design. However, its full potential has yet to be realized. Many enterprises still rely heavily on experience rather than simulation, and there is a shortage of skilled professionals who can effectively apply CAE technologies. While software tools are powerful, they require not only technical proficiency but also a deep understanding of engineering principles and practical experience. As CAE simulation technology continues to evolve and integrate with mold design, it will revolutionize traditional design methods. By simulating molds under various working conditions, designers can gain valuable insights into the forming process, leading to more efficient designs, lower risks, and faster product development cycles. The future of mold design lies in the seamless integration of simulation and engineering expertise.

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