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.

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.

Defect Minimization of an Injection Molded Plastic Component Using Conformal Cooling Channels

2021 ◽  
Vol 1019 ◽  
pp. 205-210
Author(s):  
Deepika S. Singraur ◽  
Bhushan T. Patil ◽  
Vasim A. Shaikh
Keyword(s):  
Performance Parameters ◽  
Cooling Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Molded Part ◽  
Cooling Method ◽  
Conformal Cooling Channels ◽  
Differential Shrinkage ◽  
Injection Molded ◽  
Injection Molded Plastic

The cooling process is an essential aspect while designing for uniform heat transfer between the mold and the molded part. Improper design and placement of cooling channels result in non-uniform cooling and thus results in differential shrinkage and warpage on the final product. The installation of the channels yet plays a crucial role in the cooling of the part. Conforming channels that are placed at an optimum distance from the part to enhance the cooling process. In this paper, the performance parameters of straight drilled channels are compared with the conformal cooling channels for an electric alarm box. The analysis indicates that the conformal cooling method improved and enhanced the cooling process and reduced the defects like warpage and differential shrinkage by 25.5% and 28.0% respectively.

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.

Study on the Optimization of Conformal Cooling Channels for Plastic Injection Mold

2012 ◽  
Vol 591-593 ◽  
pp. 502-506
Author(s):  
Ying Ping Qian ◽  
Yong Wang ◽  
Ju Hua Huang ◽  
Xi Zhi Zhou
Keyword(s):  
Injection Mold ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Complicated Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Popular Subject ◽  
Plastic Injection

The cooling process of injection molding is a complicated process related to thermodynamics and hydrodynamics, and it has a direct impact on quality and productivity of injection molded parts. With increasing requirements on high quality of injection molded parts, the research on the design of conformal cooling channels of injection mould gradually becomes a popular subject. The paper introduced the process of heat transfer for plastic injection mold with conformal cooling channels and its feature; analysed the optimization of conformal cooling channels; A new set of design methodology and rules is developed.

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