Simulating tool functionality

Single-example products, such as tools, molds and dies, or production-run goods, such as high-volume machined components, are often developed via trial and error. That’s an expensive hit-and-miss journey that some call “R&D.”

In this pricey, scattershot approach, prototypes are manufactured for testing, the results of which are then used to alter materials or designs. New prototypes are subsequently further tested—again and again—until a satisfactory outcome is reached. This physically iterative approach to product development delays entry to market. Additionally and most importantly, any evaluation after prototyping adds costs to program budgets. In the end, using computer-aided engineering (CAE) or finite element analysis (FEA) after the fact (when troubleshooting) gives rise to margin-crushing inefficiencies, wasted materials, lost time and schedules, expensive energy inputs and missed market opportunities, while constraining design creativity. In contrast, when used properly CAE and FEA allow for early feasibility assessment and optimization of products and assemblies before any metal is cut.

Successful new product development integrates materials and simulation technologies. A product concept can be effectively evaluated on the screen prior to developing prototypes. In addition, materials, designs, assembly and field functionality can be altered at will until an optimal solution is achieved. This virtual approach allows the generation of rich, detailed and revealing behaviors of complex materials and products. Besides, validation ought to go beyond simple pass-or-fail gauging and into correlating numerical predictions to “real life” for future use of similar models.

In addition, tool, mold and die makers and part manufacturers must continuously enhance quality, reduce costs and accelerate their product delivery processes. Still, despite these imperatives, many tool, mold and die makers cannot meet these challenges with internal resources alone. More than ever, those companies are turning to testing laboratories and engineering consultants for help in developing new tooling materials, machining processes and tool, mold and die designs.

Courtesy of Ansys

A plastic injection molding tool in Ansys’ DesignModeler software.

Courtesy of Ansys

Tool size per industry guidelines (outer) vs. an FEA-optimized tool.

Nonetheless, simulating the functionality of components prior to investment in prototyping helps negate trial and error on variations of physical prototypes. Such simulation includes materials testing and characterization, definition of design parameters and product and process validation—under accelerated conditions in the laboratory and field.