How many times can CAE simulation of casting molds reduce the number of trial mold changes
CAE simulation predicts filling and solidification defects before mold production, and data shows that mature simulation schemes can reduce the number of trial mold iterations by more than 60%.
The wheel hub mold without CAE simulation has an average of 4-5 rounds of mold modification from T0 to T2, which prolongs the project delivery cycle.
Simulation can locate the hot spot, coil air, and cold insulation positions in advance, and modify the mold cavity, runner, and cooling scheme before CNC machining.
Once the mold processing is completed and then modified, the cost of a single mold modification usually accounts for 8% -15% of the total mold price, resulting in significant economic losses.
The structural components of new energy chassis have complex shapes and large fluctuations in wall thickness. Without simulation support, the risk of trial mold failure increases by 70%.
Overseas high-end customers, especially OE supporting projects in Eastern Europe and Mexico, will directly use CAE simulation reports as pre bidding materials.
Simulate and output temperature field, flow field, and solid fraction cloud maps, and process engineers adjust the layout of gates, cooling, and exhaust based on the cloud maps.
In the development process of wheel hub molds for Xinfeng Machinery, CAE simulation is a fixed front-end link that synchronously outputs deliverable simulation reports.
Simulation is not omnipotent. If the simulation parameters deviate too much from the on-site aluminum liquid temperature, filling speed, and cooling water pressure, there may be deviations in the prediction.
The simulation model needs to be calibrated according to the actual working conditions on site, and the prediction accuracy of the calibrated model can be improved to over 85%.
Some small and medium-sized foundries skip the simulation process and rely on engineer experience to test molds in order to compress mold budgets, which is suitable for simple gravity wheel hubs.
It is difficult to bear the cost risk of skipping simulation for complex chassis components, CPC reverse pressure molds, and water-cooled LPDC wheel hub molds.
Procast simulation wheel casting mold is a high-frequency search term for process engineers in Google Keyword Planning.
Most of the visitors attracted by this type of professional content are technical decision-makers with close business proximity, and the quality of inquiries is generally high.
The simulation software version and grid division accuracy can both affect the results. If the grid size is too large, small thermal nodes cannot be identified.
The conventional grid size of the wheel hub mold is controlled at 2-3mm, and the local refinement of the chassis irregular parts is increased to 1mm to capture small defect areas.
After the simulation is completed, it is necessary to combine DFM evaluation to assess whether there are inherent defects in the casting structure that are difficult to form.
Many defects originate from casting product drawings, and simply modifying the mold cannot completely solve them. It is necessary to negotiate product optimization with the customer.
Türkiye hub factory has upgraded a large number of LPDC water-cooled molds, and more and more purchasers have begun to actively request supporting CAE simulation services.
Simulation services may slightly increase the mold quotation, but the long-term benefits are more considerable due to the comprehensive trial mold, mold modification, and delay losses.
## FAQ
Q: How many trial runs can CAE simulation reduce?
A: Mature simulation schemes reduce trial iterations by an average of over 60%.
Q: How many rounds are usually tested for non simulated wheel hub molds?
A: Typically, there are 4-5 rounds of mold modification from T0 to T2 on average.
Q: What is the recommended mesh size for wheel hub mold simulation?
A: The mainstream grid size is 2-3mm, with locally encrypted key areas.
Q: Is the simulation result necessarily consistent with the field?
A: Deviation between parameters and on-site operating conditions can lead to errors, with an accuracy of approximately 85% after calibration.
Q: Which molds are strongly recommended for CAE simulation?
A: Water cooled LPDC, CPC molds, and molds for complex new energy chassis structural components.
Q: What is the biggest risk of skipping simulation?
A: After multiple mold changes were made after processing, both cost and delivery time were out of control.
Q: Which overseas clients are required to provide simulation reports?
A: Most of the projects in Mexico and Eastern Europe involve connecting OE host factories.
Q: Can simulation solve the structural defects of the drawing itself?
A: Only able to identify, requiring collaborative customer optimization of product structure.
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