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

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.

Warpage Analysis with Straight Drilled and Conformal Cooling Channels on Front Panel Housing by Using Taguchi Method

2013 ◽  
Vol 594-595 ◽  
pp. 593-603 ◽  
Author(s):  
Z. Shayfull ◽  
S. Sharif ◽  
Azlan Mohd Zain ◽  
R. Mohd Saad ◽  
M.A. Fairuz
Keyword(s):  
Taguchi Method ◽  
Front Panel ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Thermal Distribution ◽  
Conformal Cooling Channels ◽  
Molded Parts ◽  
Differential Shrinkage

The challenging in injection molding process is to get the uniform thermal distribution on the molded parts during the cooling stage which is mainly depend on the design of the cooling channels in injection mold. Poor design of cooling channels will result a non-uniform thermal distribution which lead to a longer cycle time, differential shrinkage and warpage defects on the molded parts. In this study, the performance of conformal cooling channels compared to the straight drilled cooling channels in order to minimize the warpage on the front panel housing is evaluated. The simulation results from Autodesk Moldflow Insight (AMI) 2013 are analyzed by using Taguchi Method and Analysis of Variance (ANOVA). The analyses show that conformal cooling channels are able to improve the quality of the molded parts in term of warpage compared to the conventional straight drilled cooling channels and the results are beneficial for the molding industries which involving the precise parts.

scholarly journals 2D Heat Transfer Simulation of an Injection Mold: Comparison Between ANSYS Workbench and ANSYS Mechanical APDL

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
Hugo Luís Rodrigues ◽  
João Tiago Noversa ◽  
Leandro Fernandes ◽  
António José Pontes
Keyword(s):  
Design Procedure ◽  
Maximum Temperature ◽  
Injection Molding Process ◽  
Efficient Design ◽  
Molding Process ◽  
Cooling Channels ◽  
Average Temperature ◽  
Recent Developments ◽  
Cost Efficient ◽  
Ansys Workbench

Abstract The fabrication of conformal cooling channels (CCC's) has become easier and more affordable due to recent developments in additive manufacturing. The use of CCC's allows better cooling performance than the conventional (straight drilled) channels, in the injection molding process. The main reason for this is that the CCC's can follow the paths of the molded geometry, whereas the conventional channels made by conventional machining techniques are not able to do so. CCCs can help to reduce thermal strains and warpage by reducing cycle time and allowing for a more uniform temperature distribution. CCC, on the other hand, has a more complicated design procedure than traditional channels. Computer-Aided Engineering (CAE) simulations) are crucial to achieve an effective and cost-efficient design. This article focuses the comparison of two ANSYS modules, for results validation. The relative error between ANSYS Workbench and ANSYS Mechanical APDL varied from close to 0 to below 1 %, in the case of maximum temperature Tmax, and between 1.5 to 5.5 approximately, for the average temperature Tavg. It can be concluded that, for the most refined mesh studied, the results are close by the two modules. Therefore, the ANSYS module to work on should be used based on the purpose of the work, as well as the complexity of the CAD geometry.

Improving Warpage with Milled Groove Square Shape Conformal Cooling Channels

2016 ◽  
Vol 700 ◽  
pp. 31-41
Author(s):  
Z. Shayfull ◽  
S. Sharif ◽  
Azlan Mohd Zain ◽  
S.M. Nasir ◽  
R. Mohd Saad
Keyword(s):  
Injection Moulding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Cross Sectional ◽  
Conformal Cooling ◽  
Moulding Process ◽  
Cooling Channels ◽  
Thermal Distribution ◽  
Conformal Cooling Channels ◽  
Injection Moulding Process

Warpage is a common issue in an injection moulding process due to non-uniform temperature variation causing differential shrinkage on the moulded parts. In designing moulds for injection molding process, it is very difficult to achieve efficient cooling with uniform thermal distribution. Most of researchers focus on an optimisation of processing parameters to improve the warpage. However, the conformal cooling channels have advantages with the uniform distance between center of cooling channels and mould surfaces in order to get a better thermal distribution thus reducing the warpage. This paper presents the Milled Grooved Square Shape (MGSS) conformal cooling channels which provide more uniform in cooling and have a bigger effective cooling surface area cross sectional area and comparing to circular and others type of cooling channels with similar cross section. A case study on front panel housing is investigated and the possibility of fabrication the conformal cooling channels on hard tooling for injection moulding process which is easier to design, fabricate and assemble compared to other method are presented. The performance designs of straight drilled are compared to the two types of MGSS conformal cooling channels by using Autodesk Moldflow Insight (AMI) 2012. The analyses show that the both types of MGSS conformal cooling channel suggested can provide a more uniform thermal distribution and able to reduce the warpage on the molded part compared to the straight drilled cooling channels.

scholarly journals Warpage Optimisation on the Moulded Part with Straight Drilled and Conformal Cooling Channels Using Response Surface Methodology (RSM), Glowworm Swarm Optimisation (GSO) and Genetic Algorithm (GA) Optimisation Approaches

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1326
Author(s):  
Mohd Hazwan Mohd Hanid ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Safian Sharif ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Acrylonitrile Butadiene Styrene ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

It is quite challenging to control both quality and productivity of products produced using injection molding process. Although many previous researchers have used different types of optimisation approaches to obtain the best configuration of parameters setting to control the quality of the molded part, optimisation approaches in maximising the performance of cooling channels to enhance the process productivity by decreasing the mould cycle time remain lacking. In this study, optimisation approaches namely Response Surface Methodology (RSM), Genetic Algorithm (GA) and Glowworm Swarm Optimisation (GSO) were employed on front panel housing moulded using Acrylonitrile Butadiene Styrene (ABS). Each optimisation method was analysed for both straight drilled and Milled Groove Square Shape (MGSS) conformal cooling channel moulds. Results from experimental works showed that, the performance of MGSS conformal cooling channels could be enhanced by employing the optimisation approach. Therefore, this research provides useful scientific knowledge and an alternative solution for the plastic injection moulding industry to improve the quality of moulded parts in terms of deformation using the proposed optimisation approaches in the used of conformal cooling channels mould.

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 Dynamic conformal cooling improves injection molding

2021 ◽  
Vol 114 (1-2) ◽  
pp. 107-116
Author(s):  
Andreas Kirchheim ◽  
Yogeshkumar Katrodiya ◽  
Livia Zumofen ◽  
Frank Ehrig ◽  
Curdin Wick
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Injection Molding Process ◽  
Layer By Layer ◽  
Mold Surface ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Heating And Cooling ◽  
Conformal Cooling Channels

AbstractTo achieve a certain visual quality or acceptable surface appearance in injection-molded components, a higher mold surface temperature is needed. In order to achieve this, injection molds can be dynamically tempered by integrating an active heating and cooling process inside the mold halves. This heating and cooling of the mold halves becomes more efficient when the temperature change occurs closer to the mold surface. Complex channels that carry cold or hot liquids can be manufactured close to the mold surface by using the layer by layer principle of additive manufacturing. Laser powder bed fusion (L-PBF), as an additive manufacturing process, has special advantages; in particular, so-called hybrid tools can be manufactured. For example, complex tool inserts with conformal cooling channels can be additively built on simple, machined baseplates. This paper outlines the thermal simulation carried out to optimize the injection molding process by use of dynamic conformal cooling. Based on the results of this simulation, a mold with conformal cooling channels was designed and additively manufactured in maraging steel (1.2709) and then experimentally tested.

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

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
João Tiago Noversa ◽  
Leandro Fernandes ◽  
Hugo Luís Rodrigues ◽  
António José Pontes
Keyword(s):  
Sensitivity Analysis ◽  
Thermal Stresses ◽  
Cost Effective ◽  
Heat Transfer Analysis ◽  
Injection Molding Process ◽  
Optimization Approach ◽  
Molding Process ◽  
Ejection Time ◽  
Cooling Channels ◽  
Design Variables

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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