Additive manufacturing–assisted conformal cooling channels in mold manufacturing processes

Shinde, Mahesh S.; Ashtankar, Kishor M.

doi:10.1177/1687814017699764

Cited by 87 publications

(45 citation statements)

References 33 publications

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“…AM of tooling in injection molding of plastic components have been studied in different investigations [6,7]. In [7], optimized conformal cooling enabled by AM replaced the conventional drilled cooling and resulted in shorter cycle time, reduced waste and improved part quality.…”

Section: Introductionmentioning

confidence: 99%

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

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This paper deals with the design and production of stamping tools and dies for sheet metal components and injection molds for plastic components. Laser-based Powder Bed Fusion (LPBF) is the additive manufacturing method used in this investigation. Solid and topology optimized stamping tools and dies 3D-printed in DIN 1.2709 (maraging steel) by LPBF are approved/certified for stamping of up to 2-mm thick hot-dip galvanized DP600 (dualphase steel sheet). The punch in a working station in a progressive die used for stamping of 1-mm thick hot-dip galvanized DP600 is 3D-printed in DIN 1.2709, both with a honeycomb inner structure and after topology optimization, with successful results. 3D printing results in a significant lead time reduction and improved tool material efficiency. The cost of 3D-printed stamping tools and dies is higher than the cost of those made conventionally. The core (inserts) of an injection mold is 3D-printed in DIN 1.2709, conformal cooling optimized and 3D-printed in Uddeholm AM Corrax, and compared with the same core made conventionally. The cooling and cycle time can be improved, if the injection molding core (inserts) is optimized and 3D-printed in Uddeholm AM Corrax. This paper accounts for the results obtained in the above-mentioned investigations.

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Section: Introductionmentioning

confidence: 99%

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

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show abstract

“…However, the cooling conduits are conventionally manufactured by drilling, hence only straight channels can be generated and often attain a not uniform heat transfer. This may lead to longer cycle times, unequal cooling and warp [7]. Thus, the employment of traditional techniques for the manufacture of the inner cooling conducts of the stamping tools leads to restrictions on the final geometry of the parts.…”

Section: Introductionmentioning

confidence: 99%

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

Cortina

Arrizubieta

Calleja

et al. 2018

Metals

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Hot stamping dies include cooling channels to treat the formed sheet. The optimum cooling channels of dies and molds should adapt to the shape and surface of the dies, so that a homogeneous temperature distribution and cooling are guaranteed. Nevertheless, cooling ducts are conventionally manufactured by deep drilling, attaining straight channels unable to follow the geometry of the tool. Laser Metal Deposition (LMD) is an additive manufacturing technique capable of fabricating nearly free-form integrated cooling channels and therefore shape the so-called conformal cooling. The present work investigates the design and manufacturing of conformal cooling ducts, which are additively built up on hot work steel and then milled in order to attain the final part. Their mechanical performance and heat transfer capability has been evaluated, both experimentally and by means of thermal simulation. Finally, conformal cooling conduits are evaluated and compared to traditional straight channels. The results show that LMD is a proper technology for the generation of cooling ducts, opening the possibility to produce new geometries on dies and molds and, therefore, new products.

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“…The planar sections S conformal ∈ R 2 are separated from each other by the parametrized distance L conformal obtained from the dimensioning genetic optimization algorithms. Similarly, each planar section S conformal (i) ∈ R 2 is defined by a set of n conformal (i) ∈ R 3 nodes generated by the intersection of the set of P conformal ∈ R 3 and the edges of the facets that conform to the discrete geometry of the plastic part P' ∈ R 3 (see Equation (10)). The normal direction that defines the set of planes P conformal ∈ R 3 is coincident with the longitudinal direction of the plastic part (see Figure 8) established from the edge of the bounding box that presents a larger dimension related to the layout of the zig-zag conformal cooling channels.…”

Section: Geometrical Design Of the Conformal Cooling Channels Pathingmentioning

confidence: 99%

“…In this line, the cooling of the molded part must be as uniform and balanced as possible, so that it makes it possible to eliminate defects such as sink marks, differential shrinkage, residual stress, warping, etc. [10,11]. The design of the cooling channels plays a critical role in the performance of the injection mold [12].…”

Section: Introductionmentioning

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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Additive manufacturing–assisted conformal cooling channels in mold manufacturing processes

Cited by 87 publications

References 33 publications

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Case Study to Illustrate the Potential of Conformal Cooling Channels for Hot Stamping Dies Manufactured Using Hybrid Process of Laser Metal Deposition (LMD) and Milling

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

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