Automotive Molding

Auto parts industry is the foundation and an important part for development of automotive industry. There are about 30,000 parts in the whole vehicle and it can be divided into automotive engine system parts, automotive body system parts, chassis system parts, electrical and electronic equipment and general-purpose parts according to the functions. According to the material classification, it can be divided into metal parts and non-metal parts, of which metal parts account for about 60%-70%, and non-metal parts account for about 30%-40%.

Automotive mould refers to mold used in the automotive field, and is known as the “mother of automotive industry”. More than 90% of parts in automotive production rely on mold forming.

Generally, it takes more than 1,000 to 1,500 sets of stamping dies for a car, which accounts for about 40% of total output value of the entire car. There are about 800 sets of plastic mould, about 300 pairs of sheet metal mould and about 100 sets of die-casting mould. Automotive stamping mould are important technological equipment for automotive production. Their design and manufacturing time accounts for about 2/3 of the whole automotive development cycle, which becomes one of the main constraints. Automotive stamping dies have the characteristics of large size, complicated working surface and high technical standards, and belong to technically intensive products.

auto-1Automotive stamping mainly refer to workpieces of desired shape and size which obtained by deformation or separation of metal material from stamping dies extruded by external forces. It is widely used in automotive covers, body systems, seat system, instrument system and exhaust system, Metal parts of automotive body are almost all stamping parts, and automotive stamping parts are the downstream industries of automotive mould.

Stamping on automotive bodies are broadly divided into cover panels, beam panels, and general stamping panel. A stamping that can clearly represent characteristics of a car is a automotive panel. Therefore, the more specific automotive mould can be said to be “automotive panel stamping die”. Simply as automotive mould.

Large and medium-sized cover automotive mould is an important part of body manufacturing technology and a key link to form independent development capability of automotive. automotive mould products include automotive cover mould, tire mould, plastic interior and exterior mould, automotive lamp mould, automotive bumper mould, and instrument panel mould.

With the increase in the development of new models for passenger cars, the number of new models launched increase every year. The capacity of automotive mould market will grow rapidly in the future as automotive market grows and competition in the automotive market increases. This is also the result of rapid development in the automotive industry and the rapid development of new models.

Luo Baihui, general secretary of International Model Association, said that market demand for automotive panel mold depends mainly on the number of new models that to be launched each year, and the number of new models to be delivered depends mainly on new model development efforts of passenger cars (including car, MPV, SUV, and minibus with less than 9 seats etc).

According to category of cover parts and requirements from automotive manufacturer, the automotive cover mould can be divided into three grades: low end, middle end and high end. Among them, mold with low technical content have been oversupplied, and the market profit margin is narrow; the competition in the mid-end mold market is becoming increasingly fierce, and high-end mold with high technical content are far from meeting the market demand and have huge development space.

In the production of automotive mould, Hafo Mould has formed a set of self-own automotive mould systems.

auto-3Three-dimensional design

High-end automotive stamping die manufacturing, from design aspect, need parametric design of mold more. We need to combine software template technology to achieve secondary development actively and effectively, form a series of fixed, standardized design parameters, design templates, achieve full correlation and drive of parameters. What’s mean change CAE result, mold process, optimization of mold structure quickly through change of parameter of mold parts.

Simulation of stamping process – Computer Aided Engineering (CAE)

Manufacture of automotive mould is inseparable from an effective board forming simulation software, and high-end automotive mould require finite element simulation technology of whole process more. An effective board forming simulation software can improve success rate of high-end automotive mould development and greatly shorten manufacturing cycle of high-end automotive mould development. It can simulate and analyze the formability of automotive stamping parts, determine the difficulty of forming and the key areas that can easily appear stamping quality defects. On the other hand, it can also calculate rough of automotive stamping parts; secondly, it can also be used to selective and targeted simulation analysis for structural and process plans of automotive mould, provide quantitative analysis and judgment data for automotive mould commissioning, identify feasible commissioning solutions and provide specific technical parameters to the solution. In short, the finite element simulation of the whole process can repeatedly optimize the automotive mould structure and process plan, moreover we can adopt multiple simulations. It can be used before on-site mold debugging to quantitatively analyze and validate the feasibility and reliability of automotive mould design, timely optimize and improve mold design.

Digital mold technology

Digital automotive mould technology mainly includes the following aspects: 1, Design for manufacturability (DFM), which considers and analyzes manufacturability during design to ensure success of the process. 2, The auxiliary technology of mold surface design, to develop intelligent profile design technology. 3, CAE auxiliary analyze and simulation of stamping process, predict and resolve possible defects and forming problems. 4, Replace the traditional two-dimensional design with a three-dimensional mold structure design. 5, Mold manufacturing process using CAPP, CAM and CAT technology. 6 Under guidance of digital technology, solve the problems that arise during test die process and stamping production.

Mold processing automation

Hafo Mould is equipped with CNC machines with a double table, automatic tool changers (ATC), photoelectric control systems for automatic machining, and on-line measuring systems for workpiece. CNC machining has evolved from simple profile machining to full machining of profile and structural surfaces, from medium to low speed machining to high speed machining.

Mold material and surface treatment technology

The quality and performance of mold material is an important factor that affects quality, life and cost of mold. Ductile iron has good toughness and wear resistance, welding performance, workability and surface hardening performance. Moreover the cost is lower than that of alloy cast iron. It has been widely used in Hafo Mould’s mold design.

Scientific and information management

Scientific management keep Hafo Mould developing in the direction of Just-in-Time Manufacturing and Lean Production. Enterprise management is more precise and production efficiency is greatly improved.

Multi-position progressive die

The multi-position progressive die can complete multiple stamping processes for parts, including punching, bending, drawing and forming with partial separation and continuous forming. The mold must have high-precision guidance and fixed distance system, and equipped with automatic feeding, automatic output, safety detection and other devices. While the mold structure is complex, with many inserts, high mold manufacturing precision, difficult manufacturing and assembly process. It is an important representative of technology-intensive automotive mould.

With the advent of electric vehicles, driverless technologies and new energy vehicles, energy conservation, environmental protection and artificial intelligence and vehicle networking technologies are become increasingly important in the automotive industry. The rapid development of new energy vehicle market led to an increase in new models, which has brought huge market opportunities to the mold industry.

As new energy vehicles emphasize reduction and efficient use of energy, lightweight materials have great potential in the market. For example, TESLA Model S, 95% of body structure parts are made of aluminum alloy, Enough to see the application of new materials in light weight have become one of the core technical directions in the future especially development of lightweight metal forming, polymer material forming, and composite forming.

At the same time, with rapid development of vehicle networking technology, continuously improved electrification and intelligence degree, automotive electronic mold have also ushered in a broader market space. China’s automotive electronics mold companies are actively deploying car networking services and key components and high-value-added products such as integrated circuits, forming synergies with the automotive electronics industry. Under the background of the rapid development of new energy vehicles and smart cars, enterprises that can use mold to manufacture Intelligent Driver Interactive Vehicle products, high-end functional assemblies will have huge development space!

auto-2The global mold industry has been steadily rising since 2001, with an average growth rate of more than 5%. By 2012, the global mold industry market reached US$94.5 billion. In developed countries such as the United States, Germany, and Japan, automotive-related mold demand accounts for more than 40% of total mold demand. Based on this, the global automotive mould market has reached US$37 billion. According to proportion of automotive stamping die production value to 40% of automotive mould production value, global automotive stamping die market is about 15 billion US dollars. At present, North America, Europe, and Japan, as traditional demand markets for automotive stamping dies, still occupy an important position in global demand, and their market demand growth rate will remain at a relatively stable level in the next few years. Compared with developed countries, automotive industry in emerging economies such as China, India, Brazil and Russia is developing rapidly, and related demand has expanded demand space of the global automotive stamping die market, and will gradually become a new engine for mold demand growth globally.

The steady and rapid development of the automotive industry has created a good environment for development of automotive stamping die industry. In the production process of automotive, more than 90% of parts need to be formed by mould. It takes more than 1,000 to 1,500 sets of stamping dies to make a car. A country’s car production reflects to some extent the overall situation of country’s required automotive moulds. After 2008 financial crisis, automotive production in traditional automotive production countries such as United States, Germany and Japan recovered moderately, while demand in emerging markets such as China, India and Brazil grew rapidly. According to forecasts, global light vehicle production growth rate will reach 3.6% from 2013 to 2020, of which growth rate of developing countries will reach 5.7%, growth rate of developed countries will remain at around 1.2%, and steady development of downstream automotive industry created a good environment to the development of automotive mould.