Sensitivity Analysis of Conformal CCs for Injection Molds: 3D Transient Heat Transfer Analysis

Abstract Fabricating conformal cooling channels (CCCs) has become easier and more cost-effective because to recent advances in additive manufacturing. CCCs provide better cooling performance in the injection molding process than regular (straight drilled) channels. The main reason for this is that CCCs can follow the molded geometry's paths, but regular machining methods cannot. Thermal stresses and warpage can be reduced by using CCCs, which also improve cycle time and provide a more uniform temperature distribution. Traditional channels, on the other hand, have a more involved design technique than CCC. Computer-aided engineering (CAE) simulations are essential for establishing an effective and cost-effective design. The sensitivity analysis of design variables is the emphasis of this research, with the goal of establishing a design optimization approach in the future. The ultimate goal is to optimize the location of Cooling Channels (CCs) in order to reduce ejection time and increase temperature uniformity. It can be concluded that the parametrization performed in ANSYS Parametric Design Language (APDL), as well as the design variables used, can be applied in practice and could be relevant in future optimization approaches.

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Sensitivity analysis of conformal CCs for injection molds: 2D Transient Heat Transfer Analysis

10.21203/rs.3.rs-958556/v1 ◽

2021 ◽

Author(s):

Hugo Miguel Silva ◽

Tiago Noversa ◽

Leandro Fernandes ◽

Hugo Rodrigues ◽

António Pontes

Keyword(s):

Sensitivity Analysis ◽

Injection Molding ◽

Thermal Stresses ◽

Parametric Design ◽

Cost Effective ◽

Heat Transfer Analysis ◽

Ejection Time ◽

Cooling Channels ◽

Design Variables ◽

Optimization Methodology

Abstract Conformal Cooling Channels (CCCs) have gotten easier and more economical to manufacture in recent years. This was largely due to recent developments in additive manufacturing. The usage of CCCs in engineering applications involving injection molding provides for superior cooling performance than straight drilled channels, which have traditionally been utilized in injection molding. The fundamental reason for this is that CCCs are able to follow the molded geometry's trajectories. With the use of CCC’s, the cooling time, total injection time, thermal stresses, and warpage can all be considerably reduced. Nonetheless, the CCC design process is more difficult than that of traditional channels. The integration of computer-aided engineering (CAE) simulations is critical for achieving an effective, cost-effective design. This paper focuses the sensitivity analysis of design variables, with the intention of implementing a design optimization methodology in the future. The ultimate goal is to optimize the placement of Cooling Channels (CCs) to minimize the ejection time and maximize the uniformity of temperature distribution. It can be concluded that the parametrization done in ANSYS Parametric Design Language (APDL), as well as the selected design variables are feasible and might be useful for future optimization methodologies.

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3D Heat transfer Simulation of an injection mold: comparison between ANSYS Workbench and ANSYS Mechanical APDL

10.21203/rs.3.rs-1017293/v1 ◽

2021 ◽

Author(s):

Hugo Miguel Silva ◽

Leandro Fernandes ◽

Hugo Luís Rodrigues ◽

João Tiago Noversa ◽

António José Pontes

Keyword(s):

Design Procedure ◽

Cost Effective ◽

Injection Molding Process ◽

Machining Processes ◽

Molding Process ◽

Cooling Channels ◽

Fine Mesh ◽

Conformal Cooling Channels ◽

Heat Transfer Simulation ◽

Effective Design

Abstract Because of recent advancements in additive manufacturing, fabricating conformal cooling channels (CCCs) has become easier and more economical. In the injection molding process, CCCs provide higher cooling performance than standard (straight drilled) channels. The major reason for this is that CCCs may follow the courses of the molded geometry, whereas typical channels created using traditional machining processes cannot. Using CCCs can reduce thermal strains and warpage while also improving cycle time and achieving a more uniform temperature distribution. CCC, on the other hand, has a more complicated design procedure than traditional channels. Simulations using computer-aided engineering (CAE) are critical for achieving an effective and cost-effective design. This article compares two ANSYS modules for the purpose of validating results. It can be inferred that the two modules produce similar results for models with fine mesh. As a result, the ANSYS module to work on should be chosen depending on the job's goal as well as the CAD geometry's complexity.

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Runner Optimization for In-Mold Assembly of Multi-Material Compliant Mechanisms

Volume 2: 31st Computers and Information in Engineering Conference, Parts A and B ◽

10.1115/detc2011-48573 ◽

2011 ◽

Cited By ~ 1

Author(s):

Wojciech Bejgerowski ◽

Satyandra K. Gupta

Keyword(s):

Optimization Problem ◽

Compliant Mechanisms ◽

Compliant Mechanism ◽

Polymer Melt ◽

Injection Molding Process ◽

Optimization Approach ◽

Assembly Process ◽

Molding Process ◽

Design Variables

The runner system in injection molding process is used to supply the polymer melt from injection nozzle to the gates of final part cavities. Realizing complex multi-material mechanisms by in-mold assembly process requires special runner layout design considerations due to the existence of the first stage components. This paper presents the development of an optimization approach for runner systems in the in-mold assembly of multi-material compliant mechanisms. First, the issues specific to the in-mold assembly process are identified and analyzed. Second, the general optimization problem is formulated by identification of all parameters, design variables, objective functions and constraints. Third, the implementation of the optimization problem in Matlab® environment is described based on a case study of a runner system for an in-mold assembly of a MAV drive mechanism. This multi-material compliant mechanism consists of seven rigid links interconnected by six compliant hinges. Finally, several optimization approaches are analyzed to study their performance in solving the formulated problem. The most appropriate optimization approach is selected. The case study showed the applicability of the developed optimization approach to runner systems for complex in-mold assembled multi-material mechanism designs.

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Design Sensitivity Analysis Applied to Injection Molding Process: Injection Pressure and Multi-Gate Location Optimization

10.1115/imece2000-1223 ◽

2000 ◽

Author(s):

Kalonji K. Kabanemi ◽

Jean-François Hétu ◽

Abdessalem Derdouri

Keyword(s):

Sensitivity Analysis ◽

Injection Molding ◽

Injection Pressure ◽

Pressure Profile ◽

Design Sensitivity ◽

Design Sensitivity Analysis ◽

Injection Molding Process ◽

Molding Process ◽

Filling Fraction ◽

Design Variables

Abstract In this work, we develop a numerical simulation method to optimize the injection molding process using the design sensitivity analysis (DSA). The optimization concerns the filling stage and focuses on the number and location of gates in a mold cavity as well as the injection pressure, considered as one of the key processing parameters, in order to minimize the fill time. Since the problem to be solved involves transient flow with free surfaces, the direct differentiation method is used to evaluate the sensitivities of the Hele-Shaw, filling fraction and the energy equations with respect to the design variables used in the analysis. The mesh domain parameterization is coped with using B-spline functions. Sensitivity equations are solved by means of finite element method. The proposed numerical approach is combined with the sequential linear and quadratic programming method of the DOT optimization tools to find the new design variables at each iteration. Starting with any initial gate locations and injection pressure profile, the method enables us to find the optimal gate locations together with the optimal injection pressure profile. Finally, numerical results involving complex mold geometries are presented and discussed to assess the validity and robustness of the proposed method.

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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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Simplified optimal modeling of resin injection molding process

e-Polymers ◽

10.1515/epoly-2019-0039 ◽

2019 ◽

Vol 19 (1) ◽

pp. 369-376 ◽

Cited By ~ 2

Author(s):

Małgorzata Chwał ◽

Aleksander Muc

Keyword(s):

Theoretical Background ◽

Injection Molding Process ◽

Optimization Approach ◽

Heating Regime ◽

Molding Process ◽

Design Variables ◽

Resin Injection ◽

Full Analysis ◽

Simplified Procedure ◽

Optimal Modeling

AbstractA simplified procedure has been developed to optimize the molding processes of thermosetting resins. The proposed methodology involves the classical finite element commercial package (NISA II v. 17). Here, the theoretical background and numerical implementation of the procedure are described. Various design variables that can describe the RIM are discussed. The solved example represents the influence of the heating regime on the curing process. The results are compared with the results obtained with the use of full analysis conducted with the aid of the finite volume analysis (filling and curing stages). They demonstrate the evident advantages of using the simplified optimization approach.

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