Many manufacturers have started creating processes and prototypes with the aid of simulation software. Implementing this “soft” process not only saves them time and money, but results in even more precisely crafted products.

Many of today’s manufacturing engineers are using high-powered computer software to simulate stamping, forging, casting, molding and machining processes on screen. Without software as a means of simulating these processes, companies would physically manufacture prototypes of parts, a time and money-consuming endeavor that runs the risk of costly errors, such as tears and wrinkles, along the way. By simulating these processes, they can predict these flaws before they happen. This exciting new tool allows engineers to make improvements to the process as they are needed.

In addition, software simulation helps manufacturers figure out the best design for parts. Previously, they had to make educated guesses as to what a part should look like. If it didn’t look right, they would have to build around it in hopes that they wouldn’t have to cut a new piece of tooling. With the advent of process simulation, they deal with these problems ahead of time and on screen. This luxury eliminates the trial-and-error aspect of manufacturing.

Product development teams are the ones who, perhaps, benefit the most from simulation. Simulation allows them to simplify the try-out and soft-tooling, or prototype, phases. They can see in advance how much machining will be required and look for possible defects, saving a considerable amount of labor and material costs involved in making any hardware changes. Normally, they would have to create small production runs of a single part. Since this is now done on screen, and not in a plant, they are able to minimize engineering changes and save on material costs. They no longer have to send a die or mold back for additional machining, a process that can take six to eight weeks. Since engineers can now predict potential strains or stresses it is possible to reduce the amount of material used. This is no small accomplishment when production costs run so high.

Source: Simulation Helps Create Manufacturing Processes
Charles J. Murray
Manufacturing.net
http://www.manufacturing.net/sponsor/dn/machine/simulate.htm