Numerical study of profiled conformal cooling channels for cooling time reduction in injection mould tools

Cooling channel design is important in mould designs to achieve shorter cycles, dimensional stability and reduced part stresses. Traditionally, cooling channels have been machined into mould components to avoid interference with the ejection system, coring, cavity and other mould details. Over the years straight drilled cooling channels have given away, in part, to conformal cooling technique often using free form fabrication techniques. This paper presents a study of optimised mould design with conformal cooling channel using finite element analysis. Various configurations of conformal cooling channels have been developed. The part cooling time using the conformal cooling channels and the straight cooling channels in the mould are computed using the Pro/Mechanica Thermal FEA software. Results are presented based on temperature distribution and cooling time using steady state and transient analysis conditions. The results show a reduction in cycle time for the plastic part with conformal cooling channel design.

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Effects of cooling time of molded parts on rapid injection molds with different layouts and surface roughness of conformal cooling channels

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-019-03694-2 ◽

2019 ◽

Vol 103 (5-8) ◽

pp. 2169-2182 ◽

Cited By ~ 4

Author(s):

Chil-Chyuan Kuo ◽

Zi-Fan Jiang ◽

Jun-Hao Lee

Keyword(s):

Surface Roughness ◽

Cooling Time ◽

Conformal Cooling ◽

Cooling Channels ◽

Rapid Injection ◽

Conformal Cooling Channels ◽

Molded Parts

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Manufacture of Production Quality Injection Mold Tools Using SLS and HSM

ASME 2007 International Manufacturing Science and Engineering Conference ◽

10.1115/msec2007-31030 ◽

2007 ◽

Cited By ~ 1

Author(s):

C. M. Taylor ◽

I. P. Ilyas ◽

K. W. Dalgarno ◽

J. Gosden

Keyword(s):

Case Studies ◽

Rapid Manufacturing ◽

Injection Mold ◽

Metal Composite ◽

Injection Mould ◽

Conformal Cooling ◽

Cooling Channels ◽

Conformal Cooling Channels ◽

Near Net Shape ◽

The Impact

The use of a rapid manufacturing method to create injection mould tools offers the opportunity to create conformal cooling channels in the core/cavity inserts. Conformal cooling channels allow for better thermal management of the injection mold tool through the cycle, with the potential to reduce cycle times and/or improve product quality. However, currently available rapid manufacturing methods do not deliver the levels of accuracy and surface finish required to meet typical injection mould tool specifications. This paper reports on a hybrid approach to developing the mold inserts, which uses the rapid manufacturing process of indirect selective laser sintering (SLS), using the 3D Systems LaserForm process, to create a near net shape insert with conformal cooling channels, and then produces the net shape inserts by using high speed machining (HSM) as a finishing process. This approach to injection mold tool development has been tested through three industrial case studies. In each study existing injection mold inserts have been redesigned to give a conformally cooled tool. These have then been manufactured to near net shape in a steel/bronze metal composite through indirect SLS, and finished to production specification using HSM, EDM and polishing. Within the case studies the main aim has been to improve productivity, and the inserts have been evaluated in industrial trials in order to assess their performance in terms of cycle time, energy usage, durability and quality. The results show that significant productivity improvements and energy use reductions in injection molding are possible through the implementation of conformal cooling. Consistency of part quality and material durability have been assessed through extended molding trials, and in some cases there is a clear economic benefit to using the inserts. However, the importance of up front modelling to understand the impact of conformal cooling channels, the need for careful planning in manufacture to ensure that the required internal geometry is created, and the need for multiple representations of the required geometry to inform the different stages of the manufacture process are highlighted.

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

10.21203/rs.3.rs-1051523/v1 ◽

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.

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Manufacture of production injection mould tooling incorporating conformal cooling channels via indirect selective laser sintering

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/0954405011519042 ◽

2001 ◽

Vol 215 (10) ◽

pp. 1323-1332 ◽

Cited By ~ 25

Author(s):

K W Dalgarno ◽

T D Stewart

Keyword(s):

Selective Laser Sintering ◽

Laser Sintering ◽

Injection Mould ◽

Conformal Cooling ◽

Cooling Channels ◽

Conformal Cooling Channels

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Numerical study of effect of cooling channel configuration and size on the product cooling effectiveness in the plastic injection molding

MATEC Web of Conferences ◽

10.1051/matecconf/201819708019 ◽

2018 ◽

Vol 197 ◽

pp. 08019

Author(s):

Angger Bagus Prasetiyo ◽

Fauzun Fauzun

Keyword(s):

Injection Molding ◽

Numerical Study ◽

Plastic Injection Molding ◽

Cooling Channel ◽

Cooling Effectiveness ◽

Conformal Cooling ◽

Cooling Channels ◽

Conformal Cooling Channels ◽

Channel Configuration ◽

Plastic Injection

Injection molding is most frequently used manufacturing processes in the plastics industry. In the plastic injection molding process the cooling channel has an important role for the cooling process of the product. The good cooling channel is indicated by the ability to absorb heat from the product quickly and uniformly on the each side of the product. This study compared straight and conformal cooling channels with diameters 8 mm to know it is effects on pattern of temperature distribution in the mold and cooling effectiveness of the product inside mold using Fluent software. Analysis of virtual model images shown that those with conformal cooling channels can predict significant heat absorption compared with straight cooling channel.

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