Design and Optimization of Conformal Cooling System of an Injection Molding Chimney

2016 ◽  
Vol 850 ◽  
pp. 679-686
Author(s):  
He Li ◽  
Yi Mei ◽  
Bo Lin ◽  
Hua Qiang Xiao
Keyword(s):  
Temperature Field ◽  
Cooling System ◽  
Transfer Model ◽  
Analysis Method ◽  
Range Analysis ◽  
Straight Pipe ◽  
Cooling Systems ◽  
Conformal Cooling ◽  
Design And Optimization ◽  
Plastic Parts

Cooling system is important in the quality and the efficiency of forming plastic parts. The heat transfer model for conformal chimney cavity and straight pipe cooling system was developed employing thermal analysis module of UG software. The temperature field distributions of two cavities were analyzed. The differences in chimney forming warping deformations, shrinkage and freeze times for the two types of cooling systems were analyzed quantitatively by Moldflow software. The results showed that the temperature field distribution of the conformal cooling system was more homogeneous and the forming quality and efficiency of molding for the plastic parts was better. Finally, the cooling system parameters were optimized through orthogonal test and range analysis method.

Design of Cooling Systems for Electronic Equipment Using Both Experimental and Numerical Inputs

2003 ◽  
Author(s):  
Tunc Icoz ◽  
Yogesh Jaluria
Keyword(s):  
Numerical Simulation ◽  
Turbulent Flows ◽  
Cooling System ◽  
Electronic Cooling ◽  
Electronic Equipment ◽  
Experimental Conditions ◽  
Cooling Systems ◽  
Design And Optimization ◽  
Traditional Design ◽  
Methods Numerical

This paper presents a methodology for the design and optimization of the cooling system for electronic equipment. In this approach, inputs from both experimentation and numerical modeling are to be used concurrently to obtain an acceptable or optimal design. The experimental conditions considered are driven by the numerical simulation, and vice versa. Thus, the two approaches are employed in conjunction, rather than separately, as is the case in traditional design methods. Numerical simulation is used to consider different geometries, materials and dimensions, whereas experiments are used for obtaining results for different flow rates and heat inputs, since these can often be varied more easily in experiments than in simulations. Also, transitional and turbulent flows are more accurately and more conveniently investigated experimentally. Thus, by using both the approaches concurrently, the entire design domain is covered, leading to a rapid, convergent, and realistic design process. Two simple configurations of electronic cooling systems are used to demonstrate this approach.

Observation of Impact of Progressive Cooling System on Temperature Field Distributions on Surfaces of Injection Moulded Plastic Parts

2015 ◽  
Vol 669 ◽  
pp. 19-28
Author(s):  
Martin Seidl ◽  
Jiří Bobek ◽  
Petr Lenfeld ◽  
Jiří Habr ◽  
Luboš Bĕhálek ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Temperature Field ◽  
Technology Implementation ◽  
Complex Geometry ◽  
Cooling System ◽  
Technological Parameters ◽  
Cooling Method ◽  
Heat Quantity ◽  
Conventional Cooling ◽  
Plastic Parts

Cooling the injection moulds with using of liquid CO2 is rated among progressive and innovative tempering systems nowadays. In the ideal case this cooling method is chosen in combination with conventional drilled or milled tempering channels where the heat transfer medium flows. These wide-spread ways of cooling are not very often effective enough and they do not provide required accuracy of heat transfer control during production by injection moulding technology. Implementation of capillary tubes that bring the liquid CO2 to critical zones enables local increasing of heat transfer. Regulation of liquid CO2 amount that is injected into mould enables removal of required heat quantity in a very short time period. In this way the homogenous rate of part cooling can be achieved which is very difficult when producing the parts with complex geometry or with combination of various wall thickness. The final mechanical and physical properties of moulded parts accrue from properties of polymer material, part design and used technological parameters. This article deals with evaluation of technological parameters, concretely the cooling parameters of both the conventional cooling method and the system utilizing the cooling potential of liquid CO2. The analysis is focused on observation of temperature field distribution on injected part surfaces.

scholarly journals A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles

Polymers ◽  
2021 ◽  
Vol 13 (16) ◽  
pp. 2744
Author(s):  
Jorge Manuel Mercado-Colmenero ◽  
Abelardo Torres-Alba ◽  
Javier Catalan-Requena ◽  
Cristina Martin-Doñate
Keyword(s):  
Thermal Performance ◽  
Cycle Time ◽  
Cooling System ◽  
Plastic Material ◽  
Dynamic Performance ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Optical Part ◽  
Part Surface ◽  
Plastic Parts

The paper presents a new design of conformal cooling channels, for application in collimator-type optical plastic parts. The conformal channels that are presented exceed the thermal and dynamic performance of traditional and standard conformal channels, since they implement new sections of complex topology, capable of meeting the high geometric and functional specifications of the optical part, as well as the technological requirements of the additive manufacturing of the mold cavities. In order to evaluate the improvement and efficiency of the thermal performance of the solution presented, a transient numerical analysis of the cooling phase has been carried out, comparing the traditional cooling with the new geometry that is proposed. The evolution of the temperature profile versus the thickness of the part in the collimating core with greater thickness and temperature, has been evaluated in a transient mode. The analysis of the thermal profiles, the calculation of the integral mean ejection temperature at each time of the transient analysis, and the use of the Fourier formula, show great improvement in the cycle time in comparison with the traditional cooling. The application of the new conformal design reduces the manufacturing cycle time of the collimator part by 10 s, with this value being 13% of the total manufacturing cycle of the plastic part. As a further improvement, the use of the new cooling system reduces the amount of thickness in the collimator core, which is above the ejection temperature of the plastic material. The improvement in the thermal performance of the design of the parametric cooling channels that are presented not only has a significant reduction in the cycle time, but also improves the uniformity in the temperature map of the collimating part surface, the displacement field, and the stresses that are associated with the temperature gradient on the surface of the optical part.

Thermo-Mechanical Analysis of a Cooling System for Hot Stamping Tools

2012 ◽  
Vol 538-541 ◽  
pp. 2053-2060
Author(s):  
Fabien Mace ◽  
Jian Ping Lin ◽  
Jun Ying Min
Keyword(s):  
Heat Transfer ◽  
Cooling System ◽  
Hot Stamping ◽  
Mechanical Analysis ◽  
Transfer Model ◽  
Cooling Systems ◽  
Flow Parameters ◽  
The Relationship ◽  
Cooling Pipes ◽  
Specific Part

Several studies and design of cooling systems for hot stamping tools have already been made. The phase transformations which occur during the process are known, and numerical simulations are now very close to the reality [1]. However these studies are often related to a specific part and can hardly be extrapolated to other parts. This paper presents several results based on a thermo-mechanical analysis which can be used to make a first design of a cooling system for hot stamping tool. A theoretical study describes the heat transfer from the tools to the cooling pipes related to different flow parameters. Numerical simulation with the software COMSOL Multiphysics has been carried out to obtain results about cooling rate and maximum stress into the tool against geometry parameters. The heat transfer model used for simulation has been validated through experiment. To finish a data analysis describes the relationship between the different parameters, more specifically their impact on the cooling. With this study we can now determine which pipes’ location and size and flow properties are likely to provide the most efficient cooling system, and which parameter we must modify to optimize it.

Assessment of thermal behavior of a cooling system to reduce thermal fatigue cracks in aluminum injection molds

2020 ◽  
pp. 75-86
Author(s):  
Sergio Antonio Camargo ◽  
Lauro Correa Romeiro ◽  
Carlos Alberto Mendes Moraes
Keyword(s):  
Thermal Fatigue ◽  
Cooling System ◽  
Fatigue Cracks ◽  
Cooling Water ◽  
Thermal Conditions ◽  
Thermal Gradients ◽  
Ansys Software ◽  
Cooling Systems ◽  
Thermal Fatigue Cracks ◽  
Number Of Cycles

The present article aimed to test changes in cooling water temperatures of males, present in aluminum injection molds, to reduce failures due to thermal fatigue. In order to carry out this work, cooling systems were studied, including their geometries, thermal gradients and the expected theoretical durability in relation to fatigue failure. The cooling system tests were developed with the aid of simulations in the ANSYS software and with fatigue calculations, using the method of Goodman. The study of the cooling system included its geometries, flow and temperature of this fluid. The results pointed to a significant increase in fatigue life of the mold component for the thermal conditions that were proposed, with a significant increase in the number of cycles, to happen failures due to thermal fatigue.

Cooling Efficiencies of a NiTi-Based Cooling Process

2013 ◽  
Author(s):  
Marvin Schmidt ◽  
Andreas Schütze ◽  
Stefan Seelecke
Keyword(s):  
Solid State ◽  
Thermodynamic Analysis ◽  
Cooling System ◽  
Analysis Method ◽  
Efficiency Ratio ◽  
Cooling Process ◽  
First Results ◽  
Work Input ◽  
Underlying Mechanisms ◽  
The Impact

Energy saving and environmental protection are topics of growing interest. In the light of these aspects alternative refrigeration principles become increasingly important. Shape memory alloys (SMA), especially NiTi alloys, generate a large amount of latent heat during solid state phase transformations, which can lead to a significant cooling effect in the material. These materials do not only provide the potential for an energy-efficient cooling process, they also minimize the impact on the environment by reducing the need for conventional ozone-depleting refrigerants. Our paper, presenting first results obtained in a project within the DFG Priority Program SPP 1599 “Ferroic Cooling”, focuses on the thermodynamic analysis of a NiTi-based cooling system. We first introduce a suitable cooling process and subsequently illustrate the underlying mechanisms of the process in comparison with the conventional compression refrigeration system. We further introduce a graphical solution to calculate the energy efficiency ratio of the system. This thermodynamic analysis method shows the necessary work input and the heat absorption of the SMA in stress/strain- or temperature/entropy-diagrams, respectively. The results of the calculations underline the high potential of this solid-state cooling methodology.

Remote Heat Pipe Based Heat Exchanger Performance in Notebook Cooling

2005 ◽  
Author(s):  
Seyyed Khandani ◽  
Himanshu Pokharna ◽  
Sridhar Machiroutu ◽  
Eric DiStefano
Keyword(s):  
Heat Exchanger ◽  
Thermal Resistance ◽  
Heat Pipe ◽  
Cooling System ◽  
Temperature Drop ◽  
Operating Conditions ◽  
Cooling Systems ◽  
Temperature Variations ◽  
Non Linear ◽  
Condenser Temperature

Remote heat pipe based heat exchanger cooling systems are becoming increasingly popular in cooling of notebook computers. In such cooling systems, one or more heat pipes transfer the heat from the more populated area to a location with sufficient space allowing the use of a heat exchanger for removal of the heat from the system. In analsysis of such systems, the temperature drop in the condenser section of the heat pipe is assumed negligible due to the nature of the condensation process. However, in testing of various systems, non linear longitudinal temperature drops in the heat pipe in the range of 2 to 15 °C, for different processor power and heat exchanger airflow, have been measured. Such temperature drops could cause higher condenser thermal resistance and result in lower overall heat exchanger performance. In fact the application of the conventional method of estimating the thermal performance, which does not consider such a nonlinear temperature variations, results in inaccurate design of the cooling system and requires unnecessarily higher safety factors to compensate for this inaccuracy. To address the problem, this paper offers a new analytical approach for modeling the heat pipe based heat exchanger performance under various operating conditions. The method can be used with any arbitrary condenser temperature variations. The results of the model show significant increase in heat exchanger thermal resistance when considering a non linear condenser temperature drop. The experimental data also verifies the result of the model with sufficient accuracy and therefore validates the application of this model in estimating the performance of these systems.   This paper was also originally published as part of the Proceedings of the ASME 2005 Pacific Rim Technical Conference and Exhibition on Integration and Packaging of MEMS, NEMS, and Electronic Systems.

Perimeter Cooling Unit and Localized Row-Based Cooling Unit Transient Air Flow Effects Modeling and Characterization in Data Centers

2015 ◽  
Author(s):  
Tianyi Gao ◽  
James Geer ◽  
Bahgat G. Sammakia ◽  
Russell Tipton ◽  
Mark Seymour
Keyword(s):  
Thermal Management ◽  
Data Center ◽  
Data Centers ◽  
Cooling System ◽  
Air Flow ◽  
Cooling Systems ◽  
Dynamic Thermal Management ◽  
Hybrid Cooling ◽  
Cooling Unit ◽  
Cooling Air

Cooling power constitutes a large portion of the total electrical power consumption in data centers. Approximately 25%∼40% of the electricity used within a production data center is consumed by the cooling system. Improving the cooling energy efficiency has attracted a great deal of research attention. Many strategies have been proposed for cutting the data center energy costs. One of the effective strategies for increasing the cooling efficiency is using dynamic thermal management. Another effective strategy is placing cooling devices (heat exchangers) closer to the source of heat. This is the basic design principle of many hybrid cooling systems and liquid cooling systems for data centers. Dynamic thermal management of data centers is a huge challenge, due to the fact that data centers are operated under complex dynamic conditions, even during normal operating conditions. In addition, hybrid cooling systems for data centers introduce additional localized cooling devices, such as in row cooling units and overhead coolers, which significantly increase the complexity of dynamic thermal management. Therefore, it is of paramount importance to characterize the dynamic responses of data centers under variations from different cooling units, such as cooling air flow rate variations. In this study, a detailed computational analysis of an in row cooler based hybrid cooled data center is conducted using a commercially available computational fluid dynamics (CFD) code. A representative CFD model for a raised floor data center with cold aisle-hot aisle arrangement fashion is developed. The hybrid cooling system is designed using perimeter CRAH units and localized in row cooling units. The CRAH unit supplies centralized cooling air to the under floor plenum, and the cooling air enters the cold aisle through perforated tiles. The in row cooling unit is located on the raised floor between the server racks. It supplies the cooling air directly to the cold aisle, and intakes hot air from the back of the racks (hot aisle). Therefore, two different cooling air sources are supplied to the cold aisle, but the ways they are delivered to the cold aisle are different. Several modeling cases are designed to study the transient effects of variations in the flow rates of the two cooling air sources. The server power and the cooling air flow variation combination scenarios are also modeled and studied. The detailed impacts of each modeling case on the rack inlet air temperature and cold aisle air flow distribution are studied. The results presented in this work provide an understanding of the effects of air flow variations on the thermal performance of data centers. The results and corresponding analysis is used for improving the running efficiency of this type of raised floor hybrid data centers using CRAH and IRC units.

Inlet Air Cooling Applied to Combined Cycle Power Plants: Influence of Site Climate and Thermal Storage Systems

2008 ◽  
Vol 130 (2) ◽  
Author(s):  
Nicola Palestra ◽  
Giovanna Barigozzi ◽  
Antonio Perdichizzi
Keyword(s):  
Power Output ◽  
Parametric Analysis ◽  
Power Plants ◽  
Cooling System ◽  
Thermal Storage ◽  
Combined Cycle ◽  
Operating Conditions ◽  
Air Cooling ◽  
Ambient Conditions ◽  
Cooling Systems

The paper presents the results of an investigation on inlet air cooling systems based on cool thermal storage, applied to combined cycle power plants. Such systems provide a significant increase of electric energy production in the peak hours; the charge of the cool thermal storage is performed instead during the night time. The inlet air cooling system also allows the plant to reduce power output dependence on ambient conditions. A 127MW combined cycle power plant operating in the Italian scenario is the object of this investigation. Two different technologies for cool thermal storage have been considered: ice harvester and stratified chilled water. To evaluate the performance of the combined cycle under different operating conditions, inlet cooling systems have been simulated with an in-house developed computational code. An economical analysis has been then performed. Different plant location sites have been considered, with the purpose to weigh up the influence of climatic conditions. Finally, a parametric analysis has been carried out in order to investigate how a variation of the thermal storage size affects the combined cycle performances and the investment profitability. It was found that both cool thermal storage technologies considered perform similarly in terms of gross extra production of energy. Despite this, the ice harvester shows higher parasitic load due to chillers consumptions. Warmer climates of the plant site resulted in a greater increase in the amount of operational hours than power output augmentation; investment profitability is different as well. Results of parametric analysis showed how important the size of inlet cooling storage may be for economical results.

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