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Technologies | Molds & Tools Section


Foundry casting moulds,
Manufacturing Industrial moulds,
Manufacturing Metal moulds - for working plastics, rubber, glass,
Manufacturing Moulds, industrial, manufacturing
Moulds for forming materials - plastics, rubber, glass,
Manufacturing Moulds for metal casting





Nowadays the crucial problem in the development of new products is to reduce the time necessary for their design and manufacture while sustaining high quality and minimum development cost. To attain this record requires experts from a number of different fields as well as from services and suppliers.

The computer aided tools (CAD & 3D modeling) methods are widely used for the design of moulds. These methods are capable to create and handle technical documents, drawings; part lists, manufacturing control programs.

The requirements connected to the flexible manufacturing, the improved quality requirements need such information, which is relevant, the geometric model. There are several possibilities to extract this information from the geometric model like the feature-based methods.
The basic geometric model can be used in mould design and in process planning of mould making, and the model is also suitable for using in the rapid prototyping and rapid tooling methods.

These models should be extracted from the classical geometric 3D model using featured based selection to describe not only the elements of the mould but the interconnections between them.






The practice accumulated in moulds making can serve solving and describing tasks.

On the base of practice of the participants the new information and communication technology connected to the new business processes and collaborative project should optimize the progress.

The overall design process must be well coordinated and integrated in Concurrent Engineering methods.

Concurrent engineering is an essential approach in obtaining improved time to market in new product development. However, even as the use of design teams is achieving great success, there is a need for the use of software tools, which support the design process to be radically improved.

Some aspects are illustrated in the following topics:

1. The mould will be manufactured only for experimentation and will not be sold, or few pieces should be produced - Such moulds often should be made with softer materials, the plastic parts removed manually and/or the mould containing only one cavity in what will eventually be a multi-cavity mould. This process is right recommended for Rapid Tooling new processes.

2. The mould will be manufactured with a new material - It's seriously recommended to apply new software simulation analysis before manufacturing.






3. The mould will be manufactured with special mechanisms or instrumentation – The simulation software tools can save costs, reduce risks and improve functionalities.

4. The mould will be manufactured using new tooling methods, or it is complex and involves many mould functions. It is not certain that the mould will function as intended. – The previous application of software simulation tools will improve analysis and decision-making.

5. The mould will be employed with a new resin system that presents special requirements - Simulation tool software are essential and could simulate all states and special needs as temperature, pressure, etc…

6. The mould will be manufactured to produce a part that, even if made as designed, may not function as intended – Rapid Tooling is the most probable solution, reducing costs and risks.

7. Some aspect of the job is technically unique, for example there might be a small unique feature on an otherwise standard mould – Simulation tools should be able to determine all risks and imperfections of the new device.

8. The geometry of the mould is significantly different from any other mould that has been manufactured before – Regardless of any configuration should be analyzed and conclusively decision-support using simulation software tools.






Recently the mold tool, and die industry has become progressively more competitive worldwide.

Considerable pressure to decrease development time and production costs on the tool and die manufacturers, reduce time-to-market of the product, and finally, increase product quality emerged from clients worldwide.

The industry in developed countries focus on working on pieces that are highly value added in nature required by competition from developing countries.

Simulations allow the designer to develop precisely moulds tool designs, improving and optimizing the tooling. Optimizing designs allow using a minimum of material, resulting in reduced production costs.

Mould tools manufacturers use software analysis or simulation tools to react to each of these requirements, enabling to manufacture parts that were previously too difficult to fabricate.

Prototypes and computer simulations decreases the cost and time to market.

Optimized tooling tends to achieve longevity, further reducing production costs, fewer tooling will be manufactured and reduced production failures.

The new design methods for the mould tools, and die industry is proven to be effective in design work, the process is optimal and cost effective, using analysis software in the design process provide the following advantages:






¤Reduction in Time-to-Market

Creating and testing physical prototypes can be is a fast, low-cost and reliable process. Some products can use computer simulations that take far less time. Running software for analyses and validating designs also leads to a reduced probability of product failure late in the design cycle, or lead-time which can result in significant optimization.

¤Design verification/validation

Simulation and rapid prototyping can determine whether the design works. The 3D animations of simulations allow seeing how the tool and dies will shape and form the working material in real life, as well as the own resulting products.

¤Improving Product Quality

Analysis allows a designer without difficulty test various geometry/ flexibility / elasticity/ temperature / friction / material variants before production, something that would also be logistically possible using prototypes. These technologies result in an optimal design, which leads to higher product quality.
New concepts producing prototypes or only simulating can provide a radical testing and a proof of concept.

¤ Durability and reliability

Software analysis can provide failure and longevity analysis of tooling and dies and is normally integrated with all major CAD systems and is directly integrated with the modeling systems, the standard for 3D design.






This means that engineers can use analysis software directly on the CAD model and do not need to remodel designs to take advantage of analysis technology.

Designing tooling and dies presents unique engineering challenges, the problem to find the optimal solution, the solution that uses a minimum of material, generate a minimum amount of defects, and has the greatest longevity.

¤ Reduction in Development Costs.

Using analysis software allows for running simulations with many different iterations of material, tool geometry, forces, and temperature rapidly, regardless of the application is forging, stamping, extrusions, molds, or any other mold/tool/die application.

This is something that is currently available or logistically feasible using physical prototypes, depending on the application and specifications. Evaluating computer simulations, however, is a much cheaper alternative. Fewer physical prototypes and shorter development time lead to a less costly design process.

Developing and testing physical prototypes is sometimes an expensive procedure to undertake.

¤ Reduction in Production Costs

Increasing tool/die longevity means fewer breakdowns in production, as well as optimized designs means a minimum of material costs – these costs can rapidly become significant over large production or when working with expensive materials.





The specific applications of software analysis tools in the various disciplines of the Mold/Tool/Die industry are largely cost-effective and improve reliability as following in the next topics:

¤ Molds and Castings

§ Mold designs evaluation and analysis before the expensive production process minimizing development and redesigning costs.

§ Design and stress analysis of Mold and platen.

§ Analysis and prediction of the feature of the final molded product.

§ Thermal analysis of work material during molding process.

§ Optimal pressure analysis for blow molding applications.

§ Optimal force analysis for compression molding.


¤ Metal Stampings and Extrusions

§ Reducing the number of physical prototypes and lead times.

§ Increasing mould tool/die life.

§ Analyzing the deformability of the material early in the development cycle improving product design optimization.





§ Predicting metal flow throughout the stamping process.

§ Determining the final dimensions of the stamped parts.

§ Allowing evaluating and testing various loading schemes before the prototype phase.

§ Preventing flow induced defects such as excessive thinning of material and/or wrinkling.

§ Reducing amount of scrap material.

¤ Forgings

§ Developing forging sequences and analyzing material flow to prevent defects such as laps and cold shuts

§ Predicting work material behavior reducing die tryout time and development costs.

§ Predicting material flow and geometry of final part.

§ Evaluating forging processes and their effects on internal material stresses.

§ Conducting die stress analysis prior to first forging trials.

§ Predicting and evaluating temperatures in warm forging operations so that material properties, including friction.

§ Optimizing product design.

§ Maximizing die life.

Other analyses allowed by software analysis tools are:



Static analysis
information on internal stresses that can assist to forecast possible problems in design. This information allows tool and die manufacturers avoiding large-scale failures that could result in the inoperability of expensive manufacturing machinery such as presses and extruders. Static analysis in addition let to evaluate the product, verifying that it can reach designed functionalities.

¤ Thermal analysis
Important tool for industrial processes, allow analyzing the work materials at various levels of heating while they are being formed. Thermal analysis allows to determine the proper material temperature while it is being forged, extruded, or molded. Analysis software used in these industrial processes can perform steady state or transient thermal analysis on the tooling. The designer can obtain a realistic prediction of temperature distributions under prescribed loads and operating conditions.

¤ Nonlinear analysis
Allows to evaluate product performance within a complex, 3D-simulated environment, offering a far more accurate determination of the different factors that may cause a device failure. Nonlinear analysis tools are effective for analyzing static and dynamic problems with geometric and material non-linearity, hyper-elasticity, creep, thermo-plasticity, and viscous elasticity. Nonlinear analysis software can also analyze nonlinear contact problems involving models surface interactions with or without friction.

D&D Enterprises is associated to Labgraph Technologies SA, specialized in mould tools design, machines & equipment development, industrial layout design.

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