A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds
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TLDR
In this paper, the authors proposed a design methodology to generate optimized design configurations of conformal cooling channels in plastic injection molds, and the design of experiments (DOEs) technique was used to study the effect of the critical design parameters of conformally channels, as well as their cross-section geometries.Abstract:
Plastic injection molding is a versatile process, and a major part of the present plastic manufacturing industry. The traditional die design is limited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermomechanical) performance. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum conformal channels based on thermomechanical performance are not found in the literature. This paper proposes a design methodology to generate optimized design configurations of such channels in plastic injection molds. The design of experiments (DOEs) technique is used to study the effect of the critical design parameters of conformal channels, as well as their cross-section geometries. In addition, designs for the “best” thermomechanical performance are identified. Finally, guidelines for selecting optimum design solutions given the plastic part thickness are provided.read more
Citations
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Design and fabrication of conformal cooling channels in molds: Review and progress updates
TL;DR: Conformal cooling (CC) channels as discussed by the authors are a series of cooling channels that are equidistant from the mold cavity surfaces, they can provide more uniform and efficient cooling effects and thus improve the production quality and efficiency significantly.
Journal ArticleDOI
Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses
TL;DR: In this article, a finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels to reduce the surface temperature difference of the melt, ejection, and warpage.
Journal ArticleDOI
A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models.
Abelardo Torres-Alba,Jorge Manuel Mercado-Colmenero,Daniel Diaz-Perete,Cristina Martin-Doñate +3 more
TL;DR: The algorithm surpassed the current state of the art since it uses as input variables firstly the discrete map of temperatures of the melt plastic flow at the end of the filling phase, and secondly a set of geometrical parameters extracted from the discrete mesh together with technological and functional requirements of cooling in injection molds.
Journal ArticleDOI
Application of New Triple Hook-Shaped Conformal Cooling Channels for Cores and Sliders in Injection Molding to Reduce Residual Stress and Warping in Complex Plastic Optical Parts.
Abelardo Torres-Alba,Jorge Manuel Mercado-Colmenero,Juan de Dios Caballero-Garcia,Cristina Martin-Doñate +3 more
TL;DR: In this paper, a triple hook-shaped conformal cooling channel was proposed for optical parts of great thickness, deep cores, and high dimensional and optical requirements, and the results showed an upgrade in thermal efficiency of 267.10% in comparison with the traditional solution.
Journal ArticleDOI
SLM Manufacturing Redesign of Cooling Inserts for High Production Steel Moulds and Benchmarking with Other Industrial Additive Manufacturing Strategies.
TL;DR: Here, the cooling inserts of high production steel moulds utilized to manufacture ribs for swimming pool sinks’ plastic cages are redesigned, simulated and manufactured, taking advantage of Selective Laser Melting possibilities and without modifying the geometry of the obtained parts, thus leading to important savings of time and some global costs in the production outcomes.
References
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The application of U-shape milled grooves for cooling of injection moulds:
TL;DR: In the injection molding process, productivity and part quality depend largely on the cooling system of the injection mould as mentioned in this paper, and several cooling methods are being adopted by the mould industry.
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FEA simulation of conformal cooling within injection moulds
TL;DR: This research study presents a design methodology applicable to the design of rapid tools for utilisation on an injection moulding machine which, through its adaptation, could reduce the cycle times associated with rapid tools and improve the tool longevity.
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Performance Evaluation of a Software Engineering Tool for Automated Design of Cooling Systems in Injection Moulding
TL;DR: In this paper, a software tool for automating the design of cooling systems for injection molding and a validation of its performance is presented, where two different design methods (i.e. automatic and manual) were applied to the mould design of two thin-walled products, namely a rectangular flat box and a cylindrical container with a flat base.
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The effect of limescale on heat transfer in injection molding
Béla Zink,József Gábor Kovács +1 more
TL;DR: In this paper, the authors developed a model to investigate the effect of limescale that formed on the wall of the cooling circuit, and they concluded that 2mm thick Limescale impedes heat removal so much that the more efficient conformal cooling system can only extract as much heat as the less efficient conventional system.