Characterizations of polymer injection molding tools with conformal cooling channels fabricated by direct and indirect rapid tooling technologies

2021 ◽  
Author(s):  
Chil-Chyuan Kuo ◽  
Shao-Xuan Qiu ◽  
Guan-Yi Lee ◽  
Jun Zhou ◽  
Heng-Qian He
Keyword(s):  
Injection Molding ◽  
Rapid Tooling ◽  
Conformal Cooling ◽  
Polymer Injection ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Polymer Injection Molding

scholarly journals Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

2019 ◽  
Vol 9 (20) ◽  
pp. 4341 ◽  
Author(s):  
Chen-Yuan Chung
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Process Parameters ◽  
Large Diameter ◽  
Melt Temperature ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Highly Efficient ◽  
Conformal Cooling Channels ◽  
Filling Time

Plastic lenses are light and can be mass-produced. Large-diameter aspheric plastic lenses play a substantial role in the optical industry. Injection molding is a popular technology for plastic optical manufacturing because it can achieve a high production rate. Highly efficient cooling channels are required for obtaining a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, highly efficient three-dimensional spiral channels can be realized for conformal cooling technique. However, the design of conformal cooling channels is very complex and requires optimization analyses. In this study, finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels. According to the simulation results, the use of conformal cooling channels can reduce the surface temperature difference of the melt, ejection time, and warpage. Moreover, the optimal process parameters (such as melt temperature, mold temperature, filling time, and packing time) obtained from the design of experiments improved the fringe pattern and eliminated the local variation of birefringence. Thus, this study indicates how the optical properties of plastic lenses can be improved. The major contribution of present proposed methods can be applied to a mold core containing the conformal cooling channels by metal additive manufacturing.

Development of green conformal cooling channels for rapid tooling

2020 ◽  
Vol 111 (1-2) ◽  
pp. 109-125
Author(s):  
Chil-Chyuan Kuo ◽  
Zheng-Yan You ◽  
Seng-Jie Chang ◽  
Jie-Dui Liao ◽  
Shao-Ting Yu ◽  
...  
Keyword(s):  
Rapid Tooling ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

scholarly journals Enhancing the Structural Strength for Injection Molding Tooling With Conformal Cooling Channels Using ANSYS Software

2021 ◽  
Author(s):  
Chil-Chyuan Kuo ◽  
Zheng-Yan You
Keyword(s):  
Injection Molding ◽  
Production Rate ◽  
Thermal Management ◽  
Structural Strength ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Average Variation ◽  
Different Diameters

Abstract Injection molding of wax patterns faces increasing demands for production rate. Proper thermal management of the injection molding tooling is capable of improving the production rate. Precise temperature control is a key to shorten the cooling time using the conformal cooling channels which are conformal to the molding cavity. However, the service life of the injection molding tooling with cooling channels will reduce significantly because the structural strength will reduce obviously. In this study, the feasibility of applying the increase in the mold thickness to maintain the structural strength of the injection molding tooling with cooling channels was verified through simulation and experiments conducted. It was found that the average variation between the results of simulation and the experiment is about 24.9%. The approximately amount of the increase in the thickness required for different diameters of cooling channels can be determined according to the trend equation of y=1.3429x-2.3429. The results can provide a reference for the conformal cooling channel design.

Improved contact lens injection molding production by 3D printed conformal cooling channels

2017 ◽  
Author(s):  
Y.F. Lin ◽  
J.R. Wu ◽  
B.H. Liu ◽  
W. C. J. Wei ◽  
A. B. Wang ◽  
...  
Keyword(s):  
Injection Molding ◽  
Contact Lens ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
3D Printed

scholarly journals Automatic design of conformal cooling channels in injection molding tooling

2018 ◽  
Vol 307 ◽  
pp. 012025 ◽  
Author(s):  
Yingming Zhang ◽  
Binkui Hou ◽  
Qian Wang ◽  
Yang Li ◽  
Zhigao Huang
Keyword(s):  
Injection Molding ◽  
Automatic Design ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

scholarly journals Structural Analysis of Molds with Conformal Cooling Channels: A Numerical Study

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
Tiago Noversa ◽  
Hugo Rodrigues ◽  
Leandro Fernandes ◽  
António Pontes
Keyword(s):  
Injection Molding ◽  
Thermal Stresses ◽  
Numerical Study ◽  
Operating Conditions ◽  
Maximum Pressure ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

Abstract The manufacturing of Conformal cooling channels (CCC’s) is now easier and more affordable, owing to the recent developments in the field of additive manufacturing. The use of CCC’s allows better cooling performances than the conventional (straight-drilled) channels, in the injection molding process. The main reason is that CCC’s can follow the pathways of the molded geometry, while the conventional channels, manufactured by traditional machining techniques, are not able to. Using CCCs can significantly improve the cycle time, allow to obtain a more uniform temperature distribution, and reduce thermal stresses and warpage. However, the design process for CCC is more complex than for conventional channels. Computer-aided engineering (CAE) simulations are important for achieving effective and affordable design. This article presents important results regarding molds with new conformal cooling channels geometries. The aim is to assess the maximum pressure that the parts can be subjected to in a real injection molding application. Linear structural analyses are carried over in the Finite Element Method Software ANSYS Workbench 2020 R2, in order to analyze both the resistance and stiffness behavior of the studied geometries. The results are analyzed according to several metrics. The results were discussed and it could be concluded that some of the structures are suitable for the typical operating conditions of the injection molding process.

scholarly journals Production of injection molding tooling with conformal cooling channels using the three dimensional printing process

2000 ◽  
Vol 40 (5) ◽  
pp. 1232-1247 ◽  
Author(s):  
Emanuel Sachs ◽  
Edward Wylonis ◽  
Samuel Allen ◽  
Michael Cima ◽  
Honglin Guo
Keyword(s):  
Injection Molding ◽  
Three Dimensional ◽  
Conformal Cooling ◽  
Printing Process ◽  
Three Dimensional Printing ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Dimensional Printing
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