In the near future, Autodesk conducted a round robin seminar on Moldflow's new features and development direction as well as some practical applications of Moldflowd. It communicated with AUTODESK mold flow analysis software application experts and analyzed mold flow. A deeper understanding, next to introduce the "implicit cost of injection molding industry and MoldFlow Literacy", I hope that all people who use this part of the technology can be helpful - Single-piece production cost of plastic products Raw materials: 38% cost of tooling 20% ​​equipment cost 34% labor cost 8% The relationship between design and cost Product and mold design cost: 20%~25% Mold manufacturing cost: 15%~20% Injection molding and post-processing costs: 60%~70% Although the design cost only accounts for 20% of the total cost, it determines the manufacturing cost of 80% of the product. Less than 40% of 80% of the manufacturing cost of a product is determined by the manufacturing itself! Plastic product development costs Direct cost: 48% Hidden cost: 52% Reducing hidden costs can improve core competitiveness! How to effectively reduce the hidden costs in development Around the core cost of product development 1. Product design: stand on the standpoint of product production 2 mold design: stand mold manufacturing and product production position 3. Material properties: Provide designers with the necessary design basis 4. Production process: optimal production conditions based on product and mold design 5. Mold manufacturing: reduce defects in injection molding production Reduce hidden costs, improve quality, shorten development cycle! Predicting the impact of different materials on product quality Reduce the time and cost of material experiments! Make sure to design the best product for manufacturing For example, this case Evaluate the feasibility of the overall design Assessing the effect of wall thickness differences on product appearance Effective design can shorten the development cycle and reduce the cost of change/trial mode! The effect of pre-judgment/experimental molding on quality 1. The use of ordinary injection molding, the product of the excess deformation, resulting in product development failure 2. Through the AMI experiment and determine the gas-assisted process, the product was eventually developed successfully 3 gas-assisted process, saving 10% on one-piece materials 4. If you use AMI in advance for evaluation, you can save 60,000 mold development and trial cost Common-mode design and runner balance Through common mode: 30% reduction in mold cost 37% reduction in production costs Pre-balancing the flow path and optimizing the process Clamping force reduced from 630 tons to 340 tons Die adjustment costs reduced by 40,000 USD Die development cycle shortened by 15 days Through three-component rotary co- injection molding Reduced mold costs by 26% Reduce production costs by 42% Maximize the material loss in the production process Through optimization Material loss reduced from 129.4 grams to 64.1 grams, 60% reduction Molding cycle reduced from 54 seconds to 36 seconds, shortened by 33% Efficient and low-cost production of qualified products High rate of fire causes cracking of the product Cold material caused by low firing rate The best injection time: The injection speed directly determines the injection pressure and production cost. Reasonable V/P switching: Can reduce the injection pressure and clamping force, reducing the defect rate. Appropriate back pressure and screw speed: Melt heat 30% from electric heat, 70% from screw cutting Suitable mold temperature: 50% increase in mold temperature, 20% reduction in appearance problems, but an increase of 15% in cooling time The most effective tool for reducing hidden costs 1. Product Design - Mold Design - Trial Mold (Trial) - Mold Repair (Cost) - Mass Production Trial - Rebuild (Fee) - Production Product Design - Test Mold Manufacturing Cycle - Production Test Cycle - Final Adjustment 2. Product Design - CAE Analysis - Mold Design - Production Product Design - Structural Design - CAE Verification (Trial Mode) - Final Adjustment 1. Shorten lead time for development 2. Reduce test mold production costs 3. Reduce the trial cost 4. Problems that may occur when you avoid production in advance 5. Reduce the overall cost of PLM MF literacy is an essential quality to reduce hidden costs Insufficient design and manufacturing experience to ensure the final quality of the product—Preliminary understanding of the final product quality The ability to design innovations is not strong, and new processes cannot be quickly imported - try the effects of innovative solutions Lack of procedures for optimizing assessments does not guarantee optimization of the solution—Optimization process centered on MF Collaborative design and communication are not enough, and each department/link is fighting each other - collaborative design based on MF The MF's literacy determines the individual's comprehensive ability Product design, mold design, quality improvement, process setting, molding method, material selection MF is popularized in enterprise applications: On the basis that designers generally have MF literacy, MF applications are universally popularized in all aspects of enterprise development and production. MF in enterprise application standardization: Combining the company's existing experience, formulate design standards and process specifications for products and molds based on MF verification. For example: wall thickness design and process specifications for sink marks MF-based development process: design standards into the process, implementation of effective Know-how library, etc. Example: Sink mark design must be verified by MF Example: Sink mark design must be verified by MF Thanks to Autodesk for your support! If you have any questions, please leave a message and we will pass it to Autodesk's team of technical experts.
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