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.
Dongguan Huayuan Electronic Technology Co., Ltd , https://www.zjsiliconefactory-oem.com