Improve Mold Design Efficiency Of Automobile Parts With ZW3D Hybrid Modeling(Revised)


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In this paper, using the automobile cooling grill as an example, I will introduce ZW3D’s
mold design. I will focus on ZW3D’s hybrid modeling technology for large automobile
products in creating parting curves, splitting core cavities and electrode design solutions.

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Improve Mold Design Efficiency Of Automobile Parts With ZW3D Hybrid Modeling(Revised)

  1. 1. Improve mold design efficiency of automobile parts with ZW3D hybrid modeling Produced By: William Li, Technical Engineer, ZWSOFT
  2. 2. Abstract:In this paper, using the automobile cooling grill as an example, I will introduce ZW3D’smold design. I will focus on ZW3D’s hybrid modeling technology for large automobileproducts in creating parting curves, splitting core cavities and electrode designsolutions.Key words: ZW3D, hybrid modeling, plastic mold design1 IntroductionAutomobile manufacturing is seeing a rapid development in the industry and an everrising competitive market. The shape of the car’s plastic interiors are more and morecomplex and changes are coming faster compressing the product development cycle.One way of reducing the costs of product development is with the use of advancedCAD/CAM integration technology software. ZW3D is a design tool that integratesproduct design, sheet metal, reverse engineering, product assembly, molddevelopment and numerical control processing in one package. ZW3D’s uniquehybrid modeling technology in mold design can greatly shorten the development cycle,improve the quality of the die, reduces the cost of the mold in development andproduction processing, producing an economic benefit for the entire enterprise.The cooling grill is an important part of the car; the modeling is complex and theoverall size is large. Using traditional mold design methods, the lead time for orderingmaterial is greatly compressed by the time spent in parting, splitting the insert andelectrode design. ZW3D’s hybrid modeling technology, which is built into the product,along with a collaborative design environment allows the part manufacturing processto start earlier and improve work efficiency.
  3. 3. 2 Analysis of the status of the mold design 2.1 Most 3D CAD design software does not have specific plastic mold designmodules. They have the basic components of general modeling. The details of thecooling hole design are done one by one making its operation efficiency low. A fewspecial injection mold design products have a fixed template design process. Thecorresponding complex plastic die part designs are not flexible and practical enough. 2.2 The mold design process in software is strict; you must follow: product analysis,parting, detailed design, electrode design and material order. Every station has towait their turn.3 The explanation of ZW3D hybrid modeling technologyZW3D hybrid modeling not only supports solid and surface modeling, but it’s reallysolids and surfaces working seamlessly together. The surface data can work withsolid data as free and flexible as flipping a light switch. Make a design follow youridea!As shown below the car bumper panel is a surface and a solid, the purpose is to getthe groove shape.3.1 The traditional 3d software design methodThe traditional 3D software can’t use solids and surfaces interoperability to get theright result. It must handle the bumper panel and recessed solid individually, to getthe inside surface of the open hole through explode, delete and suture, then sewthese two surfaces to let them become an independent surface.
  4. 4. 3.2 ZW3D hybrid modeling design methodZW3D supports the bumper panel surface and the recessed solid working with eachother directly. You only need to use a Boolean operation, to add, remove or intersectshapes, to get the results you really want.
  5. 5. So ZW3D hybrid modeling is not just solids and surfaces working in the sameenvironment but real seamless integration working with each other in a single designto provide more flexible and diverse ways of making your ideas a reality.4 Hybrid modeling in the application of partingAs shown in the figure, if you want to import the car’s cooling grill to make the molddesign, due to the design defects or different data translator formats, the geometry willhave gaps or open edges; in other words, not water tight. Open edges gap <0.02 >0.02 quantity 312 52All traditional software will require a lot of time to fix the dirty product defects. For aparticularly complex product model, if you want to get a totally perfect solid, it can takeat least a day or a few days to complete it.ZW3D provides special repair tools, but more impressive is allowing you to use this
  6. 6. defective model for parting. Using ZW3D mold design, we can give the fixing job toother engineer, and mold designers can continue parting.Another way is that using the requirements of the cooling grill tolerance of 0.02. Youonly repair 52 open edges of more than 0.02 gap, and the other 312 open edges canbe ignored. With ZW3D’s unique hybrid modeling, integrated with the ability of solidsand surfaces operating seamlessly, you can accept such defective models and stillmake parting geometry.5 Hybrid modeling in the application of splitting core & cavityThe general procedure of parting is to create: parting lines - parting faces - split core &cavity regions, which is the most common surface parting principle. The parting linedetermines the core and cavity area, segmentation, generation of the outer partingfaces and internal shut-off faces. The open surfaces combined with the core & cavitysurface areas are used to trim the insert.But it always gets an error using the traditional software for parting because of thegaps in the surface. Failure to form a closed surface area makes it unable to cut.You can’t move forward, you must turn back to check and repair the product modeland ensure that the geometry is perfect.ZW3D hybrid modeling in the parting process has good tolerance, fully supportstrimming using open surface and close solids and easily gets cavity and core parts.
  7. 7. The inside of the cooling grill has a lot of irregular cooling holes. ZW3D hybridmodeling handles this situation well. There is no need to spend a lot of time increation of the internal parting surface for cooling holes. We can complete theoutside parting surface and the core cavity with blank extremely quickly, and then findthe size of the material to order. At the same time you can add a mold base andpurchase it.Similar cooling grill molds which use a huge amount of steel and non standard moldbases, the cycle time for ordering is very long which often shortens the amount of timefor design, but the problem can be solved easily using ZW3D.6 Hybrid modeling in the application of electrode designFor this cooling grill product, the cooling holes straight walls cannot be finish bymachining. Electrode processing is required. Most of the time spent in the softwareis creating parting faces, split shape, and then get cavity & core region. After that thejob can go to programming engineers for electrode design and material order. ButZW3D still can split the part cavity and cores; no time wasted waiting for completecooling hole parting face; you can instantly submit to programming engineers to order
  8. 8. materials and electrode programming. Once part processing is completed,immediately go to processing EDM; the waited time is almost zero, to realize you’reyour collaborative design.7 Conclusions:ZW3D hybrid modeling technology can easily create the parting faces for new orexisting target parts. It is completely compatible with the assembly mode that molddesign requires. In a collaborative design environment there is no need to wait forcore parts to be finished before moving on in the process. ZW3D can do the entiremold process with great flexibility.ZW3D hybrid modeling technology can not only improve the mold design efficiency,but also has great performance in product design through CNC machining.About ZW3DZW3D is all-in-one, affordable CAD/CAM for 3D design, mold making, andcomputer-aided manufacturing. It is available in three editions: Standard for 3Dmodeling, Professional for mold and die design, and Premium for advanced 3Ddesign and CAM operations, as well as five-axis milling. Free trial versions of all threeZW3D editions are available from