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.

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.

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.

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