scholarly journals Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Polymers ◽  
2021 ◽  
Vol 13 (8) ◽  
pp. 1224
Author(s):  
Chil-Chyuan Kuo ◽  
Wei-Hua Chen
Keyword(s):  
Thermal Conductivity ◽  
Injection Molding ◽  
Cooling Time ◽  
Performance Ratio ◽  
Cooling Efficiency ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Fused Deposition ◽  
Silicone Rubber Mold

Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

Optimum Cooling Channels Design and Thermal Analysis of an Injection Moulded Plastic Part Mould

2007 ◽  
Vol 561-565 ◽  
pp. 1999-2002 ◽  
Author(s):  
Abul B.M. Saifullah ◽  
Syed H. Masood
Keyword(s):  
Cooling Time ◽  
Free Form ◽  
Cooling Channel ◽  
Channel Design ◽  
Conformal Cooling Channel ◽  
Plastic Part ◽  
Element Analysis ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

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.

Study on an Optimized Configuration of Conformal Cooling Channel by Branching Law

2014 ◽  
Author(s):  
Jae Hyuk Choi ◽  
Jin Su Kim ◽  
Eun Su Han ◽  
Hyung Pil Park ◽  
Byung Ohk Rhee
Keyword(s):  
Design Method ◽  
Cooling Efficiency ◽  
Cooling Channel ◽  
Channel Design ◽  
Conformal Cooling Channel ◽  
Temperature Deviation ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Standard Design ◽  
Product Surface

Since the 3D printing technology was applied to metallic materials, the conformal cooling channel has been widely utilized for injection mold with a higher cooling efficiency. The conformal cooling channel provides higher degree of freedom in shape and size. It is more effective to apply it to convex core accumulating more heat than the concave side. However, there has not been a standard design method for the conformal cooling channel. Depending upon channel design, the cooling efficiency would not be improved. Sometimes dead flow zones could be made in the channel. Currently every engineer makes the cooling channel design of his own. In this work, we proposed an automated optimum design method for the conformal cooling channel. In the proposed design method, whole product surface is divided into smaller domains with equal thermal energy by Voronoi diagram algorithm. Then cooling channels are installed along the centers of the domains by a binary branching algorithm. The objective of the optimization was the minimization of the product surface temperature deviation. The cooling channels are branching out over the product surface through the evolutionary steps until the objective was satisfied. The injection molding CAE analysis was done by Moldflow, and the optimization by PIAnO. The sample product was an eye-glass lens product.

scholarly journals COOLING UNIFORMITY ANALYSIS of INJECTION MOLDING PLASTIC PRODUCTS WITH COOLING SYSTEM VARIATIONS USING CFD METHOD

2020 ◽  
Vol 25 (2) ◽  
Author(s):  
Angger Bagus Prasetiyo
Keyword(s):  
Injection Molding ◽  
Cooling System ◽  
Maximum Temperature ◽  
Mold Material ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Channel System ◽  
Conformal Cooling ◽  
Cfd Method ◽  
Plastic Products

The cooling system design selection plays an important role in a product cooling process in injection molding. This study presents an analysis of the uniform cooling of plastic products with a variety of cooling systems using the CFD method. Good cooling design, able to uniform the temperature drop in plastic products. There are two types of cooling system variations used, namely the conformal cooling channel system and the straight cooling channel system using the volume of fluid model with the k-epsilon turbulent model. The mold material used is steel and the plastic material used is polypropylene. The simulation results using the CFD method show that the variations in the conformal cooling channel system resulting from a decrease in temperature for each product are more uniform, as evidenced by the color of the contour experiencing light green degradation on all sides of the product, the maximum temperature value is 422, 44 ° K and the minimum temperature value is 338. , 00 ° K, while the straight cooling channel system has a non-uniform temperature reduction, as evidenced by the value with the contour color that is still orange, the maximum temperature value is 473.11 ° K.

An Outline of Methods in Machining Curved Hole

2011 ◽  
Vol 328-330 ◽  
pp. 181-185
Author(s):  
Ying Ping Qian ◽  
Yin He ◽  
Ju Hua Huang ◽  
Xi Zhi Zhou
Keyword(s):  
Injection Molding ◽  
Cooling Effect ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Rapid Cooling ◽  
Conformal Cooling ◽  
Cooling Stage ◽  
Curved Hole

Cooling stage is a key stage of injection molding. It affects both the quality and efficiency of injection molding of products. Conformal cooling channel, due to its advantages in uniform cooling and rapid cooling, could improve the cooling effect obviously. Therefore, study on methods of machining curved hole are proposed to be used for practice. In this thesis, some methods of machining curved hole and their features in general were introduced.

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

2021 ◽  
pp. 095440542199561
Author(s):  
Shaohua Han ◽  
Zhongzhong Zhang ◽  
Pengxiang Ruan ◽  
Shiwen Cheng ◽  
Dingqi Xue
Keyword(s):  
Additive Manufacturing ◽  
High Energy ◽  
Cooling Effect ◽  
High Deposition Rate ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Energy Beam ◽  
Cooling Channels ◽  
Straight Line

Additive manufacturing has been proven to be a promising technology for fabricating high-performance dies, molds, and conformal cooling channels. As one of the manufacturing methods, wire and arc additive manufacturing displays unique advantages of low cost and high deposition rate that are better than other high energy beam-based ones. This paper presents a preliminary study of fabricating integrated cooling channels by CMT-based wire and arc additive manufacturing process. The deposition strategies for fabricating circular cross-sectional cooling channels both in conformal and straight-line patterns have been investigated. It included optimizing the welding torch angle, fabricating the enclosed semicircle structure and predicting the collision between the torch and constructed part. The cooling effect test was also conducted on both the conformal cooling channel and straight-line cooling channel. The results affirmed a higher cooling efficiency and better uniform cooling effect of the conformal cooling channel than straight-line cooling channel.

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