Development of injection molding tooling with conformal cooling channels fabricated by optimal process parameters

Kuo, Chil-Chyuan; You, Zheng-Yan

doi:10.1007/s00170-018-1664-z

Cited by 20 publications

(6 citation statements)

References 25 publications

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“…It is well known that rapid tooling technology (RTT) can produce a mold economically and efficiently compared with conventional methods. A rapid tool with different cross-sectional cooling channels was developed [ 14 , 15 ]. A reduction in cooling time of about 81% was obtained.…”

Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

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Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…Epoxy resin punch and dies constructed through indirect rapid tooling technique reduce the cost involved in forming Al-Mg alloy sheets up to 87 per cent (Kuo and Li, 2016). Kuo (2018) fabricated wax filament through indirect tooling technique and manufactured wax conformal cooling channel using FDM. Injection moulding inserts developed from nylon/iron composite filament was able to fabricate 70 low-density polyethylene parts and 40 ABS parts (Masood and Song, 2004).…”

Section: Applicationsmentioning

confidence: 99%

A review on advancements in applications of fused deposition modelling process

Sathies

Senthil

Anoop

2020

RPJ

105

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Purpose Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM. Design/methodology/approach In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated. Findings The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity. Originality/value This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.

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“…According to the industry standard, the temperature of the working surface must be controlled at 3℃ for high-quality products. The main heating methods for the hot-plate include: oil heating, induction heating, 1 thin-film resistance heating, 2 infrared heating, 3 and laser heating. 4 The first one, oil heating, as the most familiar types, is a feasible access to the target temperature by designing the oil channel, but prolongs the heating time.…”

Section: Introductionmentioning

confidence: 99%

A novel method improving the temperature uniformity of hot-plate under induction heating

Wang

Chen

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the paper, a novel method to improve the uniformity of the temperature distribution on the surface of the hot-plate is presented. Firstly, the effect of magnetic flux density under coupling of the electromagnetic and heat transfer on target surface temperature is studied numerically by using the commercial simulation software COMSOL Multiphysics. To evaluate the uniformity of the temperature distribution on the target surface, the temperature nonuniformity index on the target surface was firstly employed in terms of a specific designed electric coil. Secondly, the principal components analysis combined with the orthogonal test method is employed to analyze the shape parameters and obtain optimized temperature distribution at the target surface of the hot-plate. The simulated results show that the uniformity of temperature can be greatly improved by appropriately adjusting distribution of magnetic flux and the uniform temperature distribution can be achieved on a heating surface of 130 mm in length, 130 mm in width, and 30 mm in height. Finally, the optimizations of target surface temperature on hot-plate with different target temperatures were studied as well.

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Development of injection molding tooling with conformal cooling channels fabricated by optimal process parameters

Cited by 20 publications

References 25 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

A review on advancements in applications of fused deposition modelling process

A novel method improving the temperature uniformity of hot-plate under induction heating

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