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

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.

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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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A New Approach to Conformal Cooling Channels in Injection Molding Process

DAAAM International Scientific Book 2008 ◽

10.2507/daaam.scibook.2008.50 ◽

2008 ◽

pp. 587-602

Author(s):

H. Park ◽

N. Pham

Keyword(s):

Injection Molding ◽

Injection Molding Process ◽

Molding Process ◽

Conformal Cooling ◽

New Approach ◽

Cooling Channels ◽

Conformal Cooling Channels

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Advancements in Design And Fabrication of Conformal Cooling Channels for Improvement in Plastic Injection Molding Process

10.26488/iej.12.5.1171 ◽

2019 ◽

Vol 12 (5) ◽

Author(s):

Deepika Singh S.

Keyword(s):

Injection Molding ◽

Plastic Injection Molding ◽

Injection Molding Process ◽

Molding Process ◽

Conformal Cooling ◽

Cooling Channels ◽

Conformal Cooling Channels ◽

Plastic Injection

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Effects of different cooling channels on the cooling efficiency in the wax injection molding process

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-018-2345-7 ◽

2018 ◽

Vol 98 (1-4) ◽

pp. 887-895 ◽

Cited By ~ 9

Author(s):

Chil-Chyuan Kuo ◽

Wei- Cong Xu

Keyword(s):

Injection Molding ◽

Injection Molding Process ◽

Cooling Efficiency ◽

Molding Process ◽

Cooling Channels ◽

Wax Injection

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

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.594-595.593 ◽

2013 ◽

Vol 594-595 ◽

pp. 593-603 ◽

Cited By ~ 1

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.

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Application of Intelligent Modeling Method to Optimize the Multiple Quality Characteristics of the Injection Molding Process of Automobile Lock Parts

Polymers ◽

10.3390/polym13152515 ◽

2021 ◽

Vol 13 (15) ◽

pp. 2515

Author(s):

Wei-Tai Huang ◽

Chia-Lun Tsai ◽

Wen-Hsien Ho ◽

Jyh-Horng Chou

Keyword(s):

Temperature Distribution ◽

Injection Molding ◽

Process Parameters ◽

Cooling System ◽

Injection Molding Process ◽

Molding Process ◽

Conformal Cooling ◽

Characteristic Index ◽

Average Temperature ◽

Gray Correlation

This study focuses on applying intelligent modeling methods to different injection molding process parameters, to analyze the influence of temperature distribution and warpage on the actual development of auto locks. It explores the auto locks using computer-aided engineering (CAE) simulation performance analysis and the optimization of process parameters by combining multiple quality characteristics (warpage and average temperature). In this experimental design, combinations were explored for each single objective optimization process parameter, using the Taguchi robust design process, with the L18 (21 × 37) orthogonal table. The control factors were injection time, material temperature, mold temperature, injection pressure, packing pressure, packing time, cooling liquid, and cooling temperature. The warpage and temperature distribution were analysed as performance indices. Then, signal-to-noise ratios (S/N ratios) were calculated. Gray correlation analysis, with normalization of the S/N ratio, was used to obtain the gray correlation coefficient, which was substituted into the fuzzy theory to obtain the multiple performance characteristic index. The maximum multiple performance characteristic index was used to find multiple quality characteristic-optimized process parameters. The optimal injection molding process parameters with single objective are a warpage of 0.783 mm and an average temperature of 235.23 °C. The optimal parameters with multi-objective are a warpage of 0.753 mm and an average temperature of 238.71 °C. The optimal parameters were then used to explore the different cooling designs (original cooling, square cooling, and conformal cooling), considering the effect of the plastics temperature distribution and warpage. The results showed that, based on the design of the different cooling systems, conformal cooling obtained an optimal warpage of 0.661 mm and a temperature of 237.62 °C. Furthermore, the conformal cooling system is smaller than the original cooling system; it reduces the warpage by 12.2%, and the average temperature by 0.46%.

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Improving Warpage with Milled Groove Square Shape Conformal Cooling Channels

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.700.31 ◽

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.

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Influence of the Thermoplastic Type on the Thermal Evolution of a Piezoceramic Patch During the Manufacture of a Smart Thermoplastic Part by Injection Molding Process

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4029092 ◽

2015 ◽

Vol 137 (2) ◽

Cited By ~ 1

Author(s):

Louay Elsoufi ◽

Khaled Khalil ◽

Willy Charon ◽

Remy Lachat

Keyword(s):

Injection Molding ◽

Comparative Study ◽

Piezoelectric Properties ◽

Thermal Evolution ◽

Maximum Temperature ◽

Injection Molding Process ◽

Molding Process ◽

Injection Process

The frame of the paper is the integration of PZT actuators and sensors within thermoplastic mechanical structures. The objective of the work reported here was to select the appropriate thermoplastic materials for the smart thermoplastic manufacturing. In order to reach this objective, a comparative study was realized between different thermoplastic materials taking into consideration the PZT patch maximum temperature, the overheat time of the PZT patch during injection process, and the PZT loss in piezoelectric properties due to its thermal fragility.

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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 ◽

10.3390/ma14061326 ◽

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.

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