Ideal Tech, Inc.
29777 Telegraph Road, Suite 2500,
Southfield, MI 48034 Phone 248 827 3820
Fax 248 281 0395 email - info@idealtech.net
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Engineering Services
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 | Why good source and expertise matter in CAE services - This Air Bag Cover part was initially analyzed for mold filling analysis by some other company. This part had sequencing valve gating and tool was made as per suggestions from xxx company. The tool builder and molder went through some initial tryouts only to find out that tool will not fill without exceeding the clamp tonnage and weld lines were not acceptable at all. After spending over $25000 in 7-8 tryouts, Ideal Tech was consulted for problem solving. IT expertise recognized gating and some processing issues in the first tryout and offered few suggestions to the customer. These suggestions were immediately implemented in the tool and process within few days. The tool was rerun under the supervision of IT expertise and with few processing adjustments, acceptable parts were made within few hours. This resolved the dispute of between toolmaker and molder on bad tooling or machine size and tool was shipped to the manufacturing plant. |
Lesson - Many other companies offer analysis services that are performed poorly and many details/possible problems are ignored. Due to such quick methods and lack of experience, many times the end user end up paying for initial cost of CAE as well as high costs of tool changes, engineering changes, and molding. Cheap costs or low cost suppliers may work once in a while but a quality supplier can always work for you and save in the long run. Use only expert professionals that have the experience and know how and avoid quick and cheap service providers that attract your business with big promises.
| Improper gating and product design - A battery support part had a subgate at the end of the part. Middle of the part had several thick sections and varying thickness areas. Initially the customer was reluctant to make any changes in the gating because parts were passing the field test requirements but needed to reduce heavy sink marks and voids. After several discussions about product design issues and gating locations, customer wanted to try the new solution. The tool was modified to change the gating to the middle of the part near the thick section and few thickness changes were made using the core outs and modified design. A very first tryout after these changes were implemented, cycle time was reduced from 38 sec to 29 sec and parts were perfectly molded with almost no visible marks. All parts passed the field test requirements with the reduced part thickness and weight. Total savings were in thousands of dollars vs problem solving and analysis costs. |
Lesson - Thick sections or over design may pass functional requirements but may not provide the best solution. Do not overlook the effects of poor processing or thick section problems as the failure can be random which can result in total recall of all parts or assemblies. Always optimize product design through FEA and mold analysis before any tool kick-off.
Note - Customer names, other identifications, financial details may not be listed due to customer confidentiality requirements.
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