Comparative Economic Analysis of Injection-Moulded Component with Conventional and Conformal Cooling Channels

Singh, Deepika; Joshi, Ketaki; Patil, Bhushan

doi:10.1007/s40032-021-00778-5

Cited by 11 publications

(4 citation statements)

References 11 publications

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“…Compared with conventional straight channels, CCCs reduced cooling time ranging from 10% to 57% and provided a more uniform temperature distribution [ 38 ]. Regarding the economic analyses reported in the literature [ 39 , 40 , 41 ], CCC implementation results in improved performance of products. Various cost factors are considered for cost estimation of plastic injection molding components, including the material, mold, processing and post-processing costs.…”

Section: Introductionmentioning

confidence: 99%

“…For parts with complex shapes and high precision, it is always recommended to use conformal cooling channels as they reduce defects and cycle time. Singh et al [ 40 ] studied the cost models for plastic injection molded components using conformal cooling channels versus those using conventional cooling channels. This study used a spray bottle funnel and the results showed a reduction of approximately 12% when using CCCs.…”

Section: Introductionmentioning

confidence: 99%

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Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Vargas-Isaza,

Benitez-Lozano,

Rodriguez

2023

Polymers

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Injection molds are production tools that require detailed analysis based on the quality of the resulting part, the impact on cycle times, and the expected production volume. Cooling channels also play a critical role in mold performance and product quality as they largely determine cycle time. Designs that incorporate conformal cooling channel (CCC) geometries that conform to or align with the part contour are currently being explored as an alternative to conventional cooling channel designs in injection molds. In this study, a simulation of CCC geometries was performed and their effects on mold temperatures and warpage were investigated. Two cross-sectional geometries, circular and square, were selected for a three-factor level design of experiments (DOE) analysis. The response variables used were mold temperatures and part warpage. A cup-shaped part with upper and lower diameters of 54 and 48 mm, respectively, a height of 23 mm and a thickness of 3 mm was used for the injection molded part. A comparison was also made between two materials for the injection mold, steel and polycarbonate. The DOE results showed that the distance between the CCC and the injected part and the diameter or side of the square have significant effects on the response variables for both systems (steel and polycarbonate molds). In addition, a comparison between conventional and conformal cooling channels was analyzed using a cup-shaped part and a less rigid part geometry. The finite element simulation results show a 9.26% reduction in final warpage in the cup-shaped part using CCCs compared with the conventional cooling methods in steel. When using parts with lower geometry stiffness, the use of CCCs reduced final part warpage by 32.4% in metal molds and by 59.8% in polymer molds.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Vargas-Isaza,

Benitez-Lozano,

Rodriguez

2023

Polymers

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“…With the in-depth application of 3D printing technology in the mold manufacturing industry, the actual effect and economic value of the conformal cooling channels have been widely recognized [10][11][12] . Now it is not difficult to process the conformal cooling channels, as shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

Research on Automatic Generation Technology of Double Helix Shaped conformal cooling channels for Injection Mold

Wang,

Cheng,

Wei

2023

Preprint

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The conformal cooling channel is more and more favored by the mold enterprises because of its excellent cooling performance. However, the current design of conformal cooling channel generally has the problems of complex, time-consuming and error prone design process. The spiral cooling channel is a very important cooling channel structure in injection mold, and its application is extremely common in practical mold engineering cases. For a long time, designers have had to rely on manual construction of spiral cooling channel, which is a cumbersome and inefficient design process. Inspired by the spring structure and based on the design characteristics of spiral cooling channel, this paper puts forward an automatic generation method of conformal cooling channel based on the basic requirements of conformal cooling channel design in engineering practice. The basic idea of this method firstly is to generate the initial trajectory lines and store them in a list in the specified order. Then, based on the initial trajectory line as the basic geometry, a series of control points are generated, and all control points, including the inlet and outlet coordinate points, are sorted. Finally, generate a spline curve based on the control points and scan along the spline curve with the specified cross-section to form cooling channels. Experimental results show that this method can significantly decrease the time of design and guide users to quickly complete the design, while reducing design errors to improve working efficiency.

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“…El proceso de moldeo por inyección de plástico es actualmente uno de los procesos de trasformación plástica más extendidos a nivel mundial debido a su alta productividad y a su capacidad de fabricar piezas complejas texturizadas, con colores diferentes etc [1][2][3]. El proceso de moldeo por inyección consiste básicamente en la inyección de un polímero plástico a alta temperatura y presión en el interior de la cavidad del molde [5][6][7][8]. Una vez en su interior el plástico fundido se enfría hasta un rango de temperatura capaz de garantizar la expulsión de la pieza sin deformar [9][10].…”

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Aplicación de nuevos sistemas de refrigeración conformal para moldes de inyección sostenibles

2022

Congreso Iberoamericano De Ingeniería Mecánica-Cibim 2022

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La fase de refrigeración en el tiempo ciclo del proceso de moldeo por inyección es actualmente la de mayor influencia en el gasto energético, y sostenibilidad. Los diseños tradicionales no son capaces de realizar un intercambio térmico adecuado entre el fluido refrigerante y la cavidad especialmente en piezas con geometrías complejas y núcleos profundos. En esta línea los canales de refrigeración conformal aportan una mayor flexibilidad al diseño consiguiendo un intercambio térmico entre las capas superficiales e internas de la pieza eficiente. La investigación presenta la aplicación de un nuevo sistema de refrigeración conformal para el enfriamiento de una pieza plástica compleja con gran profundidad donde el uso de la refrigeración tradicional es ineficiente. Los resultados de la investigación mejoran enormemente la uniformidad de temperaturas en la superficie de la pieza reduciendo el tiempo ciclo en más del 37%. Estos resultados se alinean perfectamente con el objetivo de mejora de la sostenibilidad y eficiencia del proceso.

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Comparative Economic Analysis of Injection-Moulded Component with Conventional and Conformal Cooling Channels

Cited by 11 publications

References 11 publications

Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Research on Automatic Generation Technology of Double Helix Shaped conformal cooling channels for Injection Mold

Aplicación de nuevos sistemas de refrigeración conformal para moldes de inyección sostenibles

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