Flexible design of small batch and multiple varieties of structural component molds

Flexible design of small batch and multiple varieties of structural component molds
Structural component orders tend to have multiple varieties and small batches. The flexible design goal of the mold is to reduce the changeover time to less than 4 hours while maintaining controllable unit costs.
Where does flexibility come from
The first layer is mold reuse. The same mold base is suitable for different cavity inserts, and only the inserts can be replaced without changing the mold base.
The second layer is interface standardization. The positioning, ejection, and waterway interface are unified, and there is no need to re align and pipe the new type.
The third layer is the parameter library. Archive the process parameters of mature products and directly call them when changing models to reduce machine debugging and errors.
Cost accounting of embedded structure
The initial investment in the embedded structure is 10% -15% higher than that of the overall mold. But only the inserts are replaced during the redesign, which costs about 30% -40% of the entire mold.
Based on a product lifecycle of 1-2 years and annual updates, the embedded structure can recoup the premium on the second product.
The precision requirements for the fitting of inserts are high. The tolerance of the mating surface is taken as H7/m6, and it cannot be loosened in the hot state, otherwise there will be gaps and dimensional drift.
The combination of quick change and standardization
After the external dimensions of the mold are unified, the same set of clamping devices can be used. The single clamping time of hydraulic quick change can be compressed within 10 minutes.
The waterway adopts an integrated joint plate, and 20-40 waterways can be docked at once. The method of taking over one by one takes 4-6 times longer than the integrated solution.
In the flexible project of structural component molds, Xinfeng Mold will make three sets of standards for mold frame, interface, and ejector into a series, which can be directly used by customers when making additional purchases.
Small batch process selection
For orders below 3000 pieces, the investment in gravity casting molds is lower. When the surface quality requirements are high, the machining allowance can be increased and supplemented.
30-20000 pieces, the cost-effectiveness of low-pressure casting is better. The balance between density and surface quality is better.
More than 20000 pieces are worth considering for multi cavity molds or automated production lines. When the batch is insufficient, it is difficult to amortize the investment in multi cavity molds.
Flexible boundary
Flexibility is not omnipotent. Excessive standardization will limit the freedom of cavity design, and complex wheel or structural components still require specialized mold frames.
Excessive number of inserts reduces the rigidity of the mold. The number of embedded blocks should be minimized, and the parting surface should avoid the critical stress area.
Reducing the changeover time to less than 4 hours is already a good level. It's better to focus on building the parameter library instead of continuing to compress the diminishing marginal returns.
Common Misconceptions
The first misconception is to equate flexibility with universality. Universal mold frames cannot adapt to all products and still need to be designed according to families.
The second misconception is neglecting the matching of tooling. The mold has been replaced, but the fixtures and gauges have not been replaced, and the time for changing the mold still cannot be reduced.
Misconception three is to only calculate the mold price. The premium of flexible molds should be compared across the entire lifecycle of multiple varieties.
Investment recovery of flexible transformation
The single investment for standardized transformation of mold frames is often between 80000 and 150000 yuan. Calculated by changing the model 12 times a year and saving 3 hours each time, it takes about two years to recover.
Projects with a frequency of less than once per quarter have limited renovation benefits. At this point, optimizing the debugging efficiency of a single set of molds is more practical.
Frequently Asked Questions
Q: How much is the cost of flexible molds?
Answer: The initial investment is 10% -15% higher, and the cost can be reduced by 30% -40% during the redesign.
Q: How long can the changeover last?
Answer: After standardization, it can be compressed within 4 hours.
Question: What is the precision of the insert fitting?
Answer: Take H7/m6 and do not loosen under hot conditions.
Q: What process should be selected for small batches?
Answer: Priority is given to gravity casting for quantities below 3000.
Q: Can the mold frame be universal?
Answer: Designed according to product family, it cannot be completely universal.
Question: Where are the boundaries of flexible design?
Answer: Complex cavities still require specialized mold frames, and there should not be too many inserts.
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