Characterization of a direct metal printed injection mold with different conformal cooling channels

Kuo, Chil-Chyuan; Jiang, Zi-Fan; Yang, Xinqi; Chu, Shao-Xuan; Wu, Jiaqi

doi:10.1007/s00170-020-05114-2

Cited by 31 publications

(10 citation statements)

References 53 publications

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“…In addition, the cooling channel should be located near the hot spot for adaptive conformal cooling. Although the previous studies used spiral cooling channels for conformal cooling of cup-shaped parts [ 34 , 35 ], the spiral channels resulted in uniform mold temperature and thus are not appropriate for the adaptive cooling of hot spots. Instead, we located the TPMS cooling structure in the upper core, as shown in Figure 5 b.…”

Section: Resultsmentioning

confidence: 99%

Adaptive Conformal Cooling of Injection Molds Using Additively Manufactured TPMS Structures

Park

2022

Polymers

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In injection molding, cooling channels are usually manufactured with a straight shape, and thus have low cooling efficiency for a curved mold. Recently, additive manufacturing (AM) was used to fabricate conformal cooling channels that could maintain a consistent distance from the curved surface of the mold. Because this conformal cooling channel was designed to obtain a uniform temperature on the mold surface, it could not efficiently cool locally heated regions (hot spots). This study developed an adaptive conformal cooling method that supports localized-yet-uniform cooling for the heated region by employing micro-cellular cooling structures instead of the typical cooling channels. An injection molding simulation was conducted to predict the locally heated region, and a mold core was designed to include a triply periodic minimal surface (TPMS) structure near the heated region. Two biomimetic TPMS structures, Schwarz-diamond and gyroid structures, were designed and fabricated using a digital light processing (DLP)-type polymer AM process. Various design parameters of the TPMS structures, the TPMS shapes and base coordinates, were investigated in terms of the conformal cooling performance. The mold core with the best TPMS design was fabricated using a powder-bed fusion (PBF)-type metal AM process, and injection molding experiments were conducted using the additively manufactured mold core. The developed mold with TPMS cooling achieved a 15 s cooling time to satisfy the dimensional tolerance, which corresponds to a 40% reduction in comparison with that of the conventional cooling (25 s).

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Section: Resultsmentioning

confidence: 99%

Adaptive Conformal Cooling of Injection Molds Using Additively Manufactured TPMS Structures

Park

2022

Polymers

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“…The optimization of the mechanical and physical properties using the Taguchi method for an LSR injection mold could also be investigated [ 32 ]. Additionally, the optimization of the curing phase of an LSR injection molding using the Moldex 3D simulation software is also an important research issue [ 33 , 34 , 35 ]. These issues are currently being investigated and the results will be presented in a later study.…”

Section: Resultsmentioning

confidence: 99%

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Kuo

Tasi

Hunag³

2022

Polymers

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Liquid silicone rubber (LSR) parts have some distinct characteristics such as superior heat stability, low-temperature flexibility, aging resistance, and chemical resistance. From an industrial standpoint, the uniform vulcanization temperature of LSR is an important research point. However, the uniformity of the vulcanization temperature of LSR has been limited since the layout of the cartridge heater incorporated in the conventional steel mold does not follow the profile of the mold cavity. Metal additive manufacturing can be used to make LSR injection molds with conformal heating channels and conformal cooling channels simultaneously. However, this method is not suitable for a mold required to develop a new LSR product. In this study, a cost-effective approach was proposed to manufacture an LSR injection mold for the pilot run of a new optical lens. A rapid tool with low vulcanization energy consumption channels was proposed, which was incorporated with both a conformal heating channel (CHC) and conformal cooling channel (CCC) simultaneously. The function of the CHC was to vulcanize the LSR in the cavity uniformly, resulting in a shorter cycle time. The function of the CCC was to keep the LSR in a liquid state for reducing runner waste. It was found that the equation of y = −0.006x3 + 1.2114x2 − 83.221x + 1998.2 with the correlation coefficient of 0.9883 seemed to be an optimum trend equation for predicting the solidification time of a convex lens (y) using the vulcanizing hot water temperature (x). Additionally, the equation of y = −0.002x3 + 0.1329x2 − 1.0857x + 25.4 with the correlation coefficient of 0.9997 seemed to be an optimum prediction equation for the solidification time of a convex lens (y) using the LSR weight (x) since it had the highest correlation coefficient. The solidification time of a convex lens could be reduced by about 28% when a vulcanizing hot water temperature of 70 °C was used in the LSR injection mold with CHC.

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“…The metal powder for printing the core insert of the mold is 316L stainless steel , the density is 7.98 g/cm 3 , and the thermal conductivity is 18.4 W/(m•K). The deformation of the core insert during the injection molding is simulated by ANSYS.…”

Section: Thermo-solid Coupling Analysis Of Mold Core Insertsmentioning

confidence: 99%

“…The circular cross-section cooling channel is the most common in mold cooling system design, but it can no longer meet the existing demand. For precision injection molds , the use of metal 3D technology to manufacture rectangular [1] , semicircular [3] , oval [4] and other irregular cross-sectional shapes [4] water channel structures can make the cooling channel surface fit Cavity wall to improve cooling effect.…”

Section: Introductionmentioning

confidence: 99%

Design and process parameter optimization of injection mold conformal cooling channel based on 3D printing

Yuan

Zhong²,

Pu³

et al. 2022

International Conference on Advanced Sensing and Smart Manufacturing (ASSM 2022)

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Aiming at the problems that the distance between the existing section cooling channel structure and the cavity wall is not constant, a type of runway section cooling channel structure was proposed. Based on the traditional channel design method, the channel design method of "line -plane-body" was improved. Using the Cosmetic bottle caps as research object, the runway cross section type cooling structure was designed, and the injection molding process parameters were optimized through orthogonal test, and obtained the optimal combination of process parameters, the results show that compared with before optimization of process parameters, plastic parts warp distortion was reduced by 11.6%, finally through the hot solid coupling analysis, show that the structure of the thermal stress distribution uniformity, Reduce the phenomenon of stress concentration in the water channel of the mold insert, ensure the service life of the insert, and have a wide range of applications in the structure of plastic parts with double wall surface.

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Characterization of a direct metal printed injection mold with different conformal cooling channels

Cited by 31 publications

References 53 publications

Adaptive Conformal Cooling of Injection Molds Using Additively Manufactured TPMS Structures

Adaptive Conformal Cooling of Injection Molds Using Additively Manufactured TPMS Structures

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Design and process parameter optimization of injection mold conformal cooling channel based on 3D printing

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