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Journal ArticleDOI

Performance Evaluation of a Software Engineering Tool for Automated Design of Cooling Systems in Injection Moulding

01 Jan 2013-Procedia CIRP (Elsevier)-Vol. 7, pp 270-275

AbstractThis paper presents a software tool for automating the design of cooling systems for injection moulding and a validation of its performance. Cooling system designs were automatically generated by the proposed software tool and by applying a best practice tool engineering design approach. The 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. Injection moulding process simulations based on the finite element method were performed to assess the quality of the moulded parts. Results indicate the tool is capable of generating feasible cooling solutions. Recommendations are provided for improving the performance of the tool.

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Citations
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Journal ArticleDOI
Abstract: For product designers, tools and techniques are essential in driving the design cycle. Nevertheless, their employment usually is implicit, while passing over e.g. the design and project environments empowering their adequate use. This publication presents an overview of approaches in structuring and using tools/techniques, based on the effectuation of creativity and decision-making in the design environment. In elaborating on characteristics of tools/techniques and ensuing ways of selecting them, the designer's portfolio of tools/techniques is characterised. Representative problems of tool/technique usage are depicted and contextualised by illustrating their industrial application. Prospects for future developments are also reviewed

85 citations


Journal ArticleDOI
TL;DR: The cooling channels designed by the algorithms has very simple connectivity and can achieve effective conformal cooling for the models with complex shapes and can be fabricated by copper duct bending instead of expensive selective laser sintering.
Abstract: Designing cooling channels for the thermoplastic injection process is a very important step in mold design. A conformal cooling channel can significantly improve the efficiency and the quality of production in plastic injection molding. This paper introduces an approach to generate spiral channels for conformal cooling. The cooling channels designed by our algorithms has very simple connectivity and can achieve effective conformal cooling for the models with complex shapes. The axial curves of cooling channels are constructed on a free-form surface conformal to the mold surface. With the help of boundary-distance maps, algorithms are investigated to generate evenly distributed spiral curves on the surface. The cooling channels derived from these spiral curves are conformal to the plastic part and introduce nearly no reduction at the rate of coolant flow. Therefore, the channels are able to achieve uniform mold cooling. Moreover, by having simple connectivity, these spiral channels can be fabricated by copper duct bending instead of expensive selective laser sintering.

66 citations


Additional excerpts

  • ...A recent effort to automate the design of cooling system is made in [9]....

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Journal ArticleDOI
TL;DR: A statistically based model predictive control algorithm was developed for controlling part quality with manipulated variables coolant flow rate and coolant temperature and replaces the need of off-line quality measurement and provides real-time injection modeling quality control.
Abstract: Quality measurement on injection molded parts are related to process parameter data.The data experimentation data is analyzed using statistical methods (PCA), (ICA) and (ANOVA).Models are constructed to predict a quality index based on data analysis results.A MPC scheme that allows for on-line quality control was developed using the models.The presented scheme is extendable to a variety of manufacturing processes. Quality control is an important aspect of manufacturing processes. Product quality of injection molded parts is influenced by the injection molding process. In this study statistical tools were used to develop a model that relates injection molding process variables to part quality. A statistically based model predictive control algorithm was developed for controlling part quality with manipulated variables coolant flow rate and coolant temperature. This approach replaces the need of off-line quality measurement and provides real-time injection modeling quality control.

33 citations


Journal ArticleDOI
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.

15 citations


01 Dec 2018
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.

10 citations


References
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Journal ArticleDOI
Abstract: A detailed formulation is presented for simulating the injection-molding filling of thin cavities of arbitrary planar geometry. The modelling is in terms of generalized Hele-Shaw flow for an inelastic, non-Newtonian fluid under non-isothermal conditions. A hybrid numerical scheme is employed in which the planar coordinates are described in terms of finite elements and the gapwise and time derivatives are expressed in terms of finite differences. The simulation is applied to the filling of a two-gated plate mold having an intentionally unbalanced runner system. Good agreement is obtained with experimental results in terms of short-shot sequences, weldline formation and pressure traces at prescribed points in the cavity.

464 citations


Book
01 Mar 1987
Abstract: How to make injection molds , How to make injection molds , مرکز فناوری اطلاعات و اطلاع رسانی کشاورزی

239 citations


Journal ArticleDOI
TL;DR: A model of the automated synthesis process is provided as a context to discuss research in the area and some guidelines are presented to help researchers and designers find approaches to solving their particular design problems using computational design synthesis.
Abstract: The field of computational design synthesis has been an active area of research for almost half a century. Research advances in this field have increased the sophistication and complexity of the designs that can be synthesized, and advances in the speed and power of computers have increased the efficiency with which those designs can be generated. Some of the results of this research have begun to be used in industrial practice, yet many open issues and research challenges remain. This paper provides a model of the automated synthesis process as a context to discuss research in the area. The varied works of the authors are discussed as representative of the breadth of methods and results that exist under the field of computational design synthesis. Furthermore, some guidelines are presented to help researchers and designers find approaches to solving their particular design problems using computational design synthesis. DOI: 10.1115/1.2013289

118 citations


"Performance Evaluation of a Softwar..." refers background in this paper

  • ...Although automating design problems has been extensively investigated over the past 30 years [4], not much literature addresses the problem of automating injection moulding cooling design....

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Journal ArticleDOI
TL;DR: This research extends the previous investigation of the automation of the preliminary design stage to the layout design stage of the cooling system design process, and develops a framework for fuzzy evaluation of the layout designs to rate the various design alternatives generated.
Abstract: This research extends our previous investigation of the automation of the preliminary design stage to the layout design stage of the cooling system design process. While the functional aspects of the cooling system are considered during the preliminary design stage, the layout design stage addresses both the functionality and manufacturability of the design. A graph structure is devised to capture a given preliminary design and a graph traversal algorithm is developed to generate candidate cooling circuits from the graph structure. Heuristic search is employed to develop the cooling circuits into the layout designs by generation of tentative manufacturing plans. A framework for fuzzy evaluation of the layout designs is developed to rate the various design alternatives generated. An experimental system is implemented to verify the feasibility of the approach, and examples generated from the system are presented to illustrate the major steps of the automatic design process.

61 citations


Book
01 Jan 2002
TL;DR: This .NET-ready Windows programming guide shows you how to get the most out of Windows Forms-the next-generation Windows programming class library and discovers how to use C# to create dynamic user interfaces and graphical outputs for Windows applications.
Abstract: "Look it up in Petzold" remains the last word on Windows development. In this .NET-ready Windows programming guide, the best-selling author shows you how to get the most out of Windows Forms-the next-generation Windows programming class library. You'll discover how to use C# to create dynamic user interfaces and graphical outputs for Windows applications. With dozens of examples of client applications to illustrate common techniques and plenty of no-nonsense advice on best programming practices, you'll be C# sharp in no time. Topics covered in this guide include: * A tour of C# * Windows Forms * Essential structures * An exercise in text output * Lines, curves, and area fills * Tapping into the keyboard * Pages and transforms * Taming the mouse * Text and fonts * The timer and time * Images and bitmaps * Buttons, labels, and scrolls * B'ers and other splines * Menus * Paths, regions, and clipping * Dialog boxes * Brushes and pens * Edit, list, and spin controls * Font fun * Toolbars and status bars * Printing * Tree view and List view * Metafiles * Clip, drag, and drop INCLUDED ON CD-ROM: * Sample source code for all the examples presented in the book For customers who purchase an ebook version of this title, instructions for downloading the CD files can be found in the ebook.

47 citations


"Performance Evaluation of a Softwar..." refers methods in this paper

  • ...The method and algorithms for cooling generation have been implemented using C#© [11]....

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