Development of a Smart Plastic Injection Mold with Conformal Cooling Channels

Park, Hong Seok; Dang, Xuan-Phuong

doi:10.1016/j.promfg.2017.07.020

Cited by 79 publications

(34 citation statements)

References 13 publications

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“…Accordingly, heat transfer rate increases as the cycle time decreases. These results have accordance with existing literature [1][2][3][4][5][6][7][8][9]. For 1m/s velocity rate, the SC and SFC required pump power is 0.157 W and 11.7…”

Section: Resultssupporting

confidence: 91%

“…Therefore better product quality was obtained in injection molds with conformal cooling channels [3][4][5][6][7][8][9]. The fact that the cost of production is high in metal molds produced with the additive manufacturing method makes it necessary to produce the conformal cooling channel design with the desired performance.…”

Section: Introductionmentioning

confidence: 99%

“…Numerical and experimental investigations revealed that % 12.8 shorter cycle time with conformal cooling channels. In addition Park and Dang [9] developed comformal cooling channel for plastic injection mold.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Design of Conformal Cooling Channels Using Numerical Methods in a Metal Mold and Calculating Exergy Destruction in Channels

Bolattürk¹,

Ipek

Kurtuluş

et al. 2018

Scientia Iranica

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Shorter cycle times, better product quality and less product outage can be possible with faster cooling. But mold cooling channels can only be made in linear directions and limited forms via classical manufacturing methods. Therefore, it limits that performance of mold cooling. Developed in recent years additive manufacturing technologies are capable of building complex geometries and monoblock 3D products. With this technology it is possible to produce metal molds with conformal cooling channels in different forms and capable of qualified cooling. In this study, conformal cooling channels were designed in order to achieve optimum cooling in monoblock permanent mold. In this study, CFD (Computational Fluid Dynamic) analyses are performed to steady stead conditions for designed conformal cooling channels and classical cooling channel mold. Pressure drops, cooling channel outlet temperatures and exergy destructions are calculated depending on the flow velocity rate in channels. The numerical investigations of the cooling process have shown that approximately 5% higher cooling performance can be achieved with conformal cooling channels. However, the pressure drop in the conformal cooling is observed to be higher than classical cooling channel. In addition, exergy destruction in the conformal cooling channel is approximately 12% greater than the classical cooling channel.

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Section: Resultssupporting

confidence: 91%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Design of Conformal Cooling Channels Using Numerical Methods in a Metal Mold and Calculating Exergy Destruction in Channels

Bolattürk¹,

Ipek

Kurtuluş

et al. 2018

Scientia Iranica

View full text Add to dashboard Cite

show abstract

“…Kitayama et al [21] performed a multi-objective design optimization in order to maximize the minimum weld line temperature for weld lines reduction and to minimize the clamping force, achieving as a result an increase in the quality of the product. Park et al [22] presented the development of an injection mold with conformal cooling channels for manufacturing a free form industrial component with variable thickness. Their study indicated that conformal cooling channels decrease the cycle time by about 30% in comparison to traditional cooling systems.…”

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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“…Numerical analysis and experimental results are consistent with each other and have a 12.8% shorter cycle time period with conformal cooling channels. In addition, Park and Dang [17] developed a conformal cooling channel for plastic injection mold. The results of this study showed 30% shorter cycle time with conformal cooling channels.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Transient Numerical Simulation of Solidification and Thermal Behavior of Metal Molds with Conformal Cooling Channels

et al. 2018

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The cooling process in metal molds is one of the important factors in the solidi cation process of molten metal. Molding defects, such as hot spot defects and warping, are usually present in cast products when cooling is not uniform. However, quali ed and faster cooling positively a ects product quality. Molding is one of the important processes both in terms of cycle time and product quality, with permanent mold casting, high-quality liquid metal casting, and quality product. Selective Laser Melting (SLM) method was used to design metal mold cores with unique cooling channels to be compactly produced. The e ects of the designed cooling channels, heat transfer, and solidi cation of the molten metal are studied in transient numerical terms. The temperature distributions at the 1st, 3rd, and 5th seconds after casting were obtained, and the solidi cation processes were investigated according to the standard cooling channels of the original cooling channels. According to the results obtained, it was observed that solidi cation would function better in the originally designed cooling channels.

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Development of a Smart Plastic Injection Mold with Conformal Cooling Channels

Cited by 79 publications

References 13 publications

Design of Conformal Cooling Channels Using Numerical Methods in a Metal Mold and Calculating Exergy Destruction in Channels

Design of Conformal Cooling Channels Using Numerical Methods in a Metal Mold and Calculating Exergy Destruction in Channels

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

Investigation of Transient Numerical Simulation of Solidification and Thermal Behavior of Metal Molds with Conformal Cooling Channels

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