A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Jahan, Suchana A.; El-Mounayri, Hazim

doi:10.3390/app8122567

Cited by 31 publications

(19 citation statements)

References 36 publications

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“…The simulation model was adjusted to the measurement results by considering the gap between the mold inserts. More recently Jahan et al [25] proposed a modeling procedure for designing optimized layouts of conformal cooling systems in injection molding. They applied the design of experiments (DOEs) methodology in order to analyze the influence of the main design dimensions, as well as the cross-section topologies.…”

Section: Background and Related Workmentioning

confidence: 99%

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

et al. 2020

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This paper presents a new method for the automated design of the conformal cooling system for injection molding technology based on a discrete multidimensional model of the plastic part. The algorithm surpasses the current state of the art since it uses as input variables firstly the discrete map of temperatures of the melt plastic flow at the end of the filling phase, and secondly a set of geometrical parameters extracted from the discrete mesh together with technological and functional requirements of cooling in injection molds. In the first phase, the algorithm groups and classifies the discrete temperature of the nodes at the end of the filling phase in geometrical areas called temperature clusters. The topological and rheological information of the clusters along with the geometrical and manufacturing information of the surface mesh remains stored in a multidimensional discrete model of the plastic part. Taking advantage of using genetic evolutionary algorithms and by applying a physical model linked to the cluster specifications the proposed algorithm automatically designs and dimensions all the parameters required for the conformal cooling system. The method presented improves on any conventional cooling system design model since the cooling times obtained are analogous to the cooling times of analytical models, including boundary conditions and ideal solutions not exceeding 5% of relative error in the cases analyzed. The final quality of the plastic parts after the cooling phase meets the minimum criteria and requirements established by the injection industry. As an additional advantage the proposed algorithm allows the validation and dimensioning of the injection mold cooling system automatically, without requiring experienced mold designers with extensive skills in manual computing.

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Section: Background and Related Workmentioning

confidence: 99%

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

et al. 2020

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“…An example of prediction using numerical modeling can be shown from published research work of the authors [1]. This includes a simple transient thermal simulation on a plastic injection mold and predicting the total cooling time.…”

Section: Predict Using Numerical Modelingmentioning

confidence: 99%

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

Jahan

El-Mounayri

Tovar

et al. 2018

Mechanics of Additive and Advanced Manufacturing, Volume 8

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Additive Manufacturing(AM), 3D printing, rapid prototyping, or rapid tooling refer to a range of technologies that are capable of translating virtual CAD model data into physical model. It is executed in growing number of applications nowadays. A wide range of materials are currently being used to produce consumer products and production tools. AM has brought in revolutionary changes in traditional manufacturing practices. Yet, there are certain drawbacks that hinder its advancement at mass manufacturing. High cost associated with AM is one of them. Using 3D printed tooling can provide long-time cost effectiveness and better product quality. Additively manufactured injection molds can increase the cooling performance, reduce production cycle time, and improve surface finish and part quality of the final plastic product. Yet, manufacturers are still not using the printed molds for industrial mass production. Numerical analysis can provide approximation of such improved performance, but, factual experimental results are necessary to satisfy performance criteria of molds to justify the large investment into tooling for existing industries. In this research work, a desktop injection molding machine is used to evaluate performance of 3D printed molds to develop a cost and performance analysis tool. It serves as a baseline to predict the performance of molds in real-time mass manufacturing of consumer products. The analysis describes how appropriate the estimation can be from any simulation study of molds, how much the scaling down of tool and molding system can affect the prediction of actual performance, what correction factors can be used for better approximation of performance matrices. Several "scaled down" prototypes of injection molds have been used. They have design variations as: with or without cooling system, conformal or straight cooling channels, solid or lattice matrix, and metal or tough resin as the mold material. The molds are printed in in-house printing machines and can also be printed online with limited charges. This also provides an excellent demonstration of using inexpensive material and manufacturing process, such as resin to estimate the performance of highly expensive 3D printed stainless steel molds. The work encompasses a framework to reduce overall cost of implementing AM, by lowering time and monetary expenses during the research and development, and prototyping phases.

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“…A designed geometry with a wide variation in the thickness ratios can originate thermally induced residual stress during the injection cooling process [10]. Residual stress results in a slight local reduction of the optical properties, and therefore, also of the transmitted light [11].…”

Section: Introductionmentioning

confidence: 99%

Application of New Triple Hook-Shaped Conformal Cooling Channels for Cores and Sliders in Injection Molding to Reduce Residual Stress and Warping in Complex Plastic Optical Parts

et al. 2021

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The paper presents a new design of a triple hook-shaped conformal cooling channels for application in optical parts of great thickness, deep cores, and high dimensional and optical requirements. In these cases, the small dimensions of the core and the high requirements regarding warping and residual stresses prevent the use of traditional and standard conformal cooling channels. The research combines the use of a new triple hook-shaped conformal cooling system with the use of three independent conformal cooling sub-systems adapted to the complex geometric conditions of the sliders that completely surround the optical part under study. Finally, the new proposed conformal cooling design is complemented with a small insert manufactured with a new Fastcool material located in the internal area of the optical part beside the optical facets. A transient numerical analysis validates the set of improvements of the new proposed conformal cooling system presented. The results show an upgrade in thermal efficiency of 267.10% in comparison with the traditional solution. The increase in uniformity in the temperature gradient of the surface of the plastic part causes an enhancement in the field of displacement and in the map of residual stresses reducing the total maximum displacements by 36.343% and the Von—Mises maximum residual stress by 69.280% in comparison with the results obtained for the traditional cooling system. Additionally, the new design of cooling presented in this paper reduces the cycle time of the plastic part under study by 32.61%, compared to the traditional cooling geometry. This fact causes a very high economic and energy saving in line with the sustainability of a green mold. The improvement obtained in the technological parameters will make it possible to achieve the optical and functional requirements established for the correct operation of complex optical parts, where it is not possible to use traditional cooling channels or standard conformal cooling layouts.

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A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Cited by 31 publications

References 36 publications

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

Application of New Triple Hook-Shaped Conformal Cooling Channels for Cores and Sliders in Injection Molding to Reduce Residual Stress and Warping in Complex Plastic Optical Parts

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