Dynamic conformal cooling improves injection molding

Kirchheim, Andreas; Katrodiya, Yogeshkumar; Zumofen, Livia; Ehrig, Frank; Wick, Curdin

doi:10.1007/s00170-021-06794-0

Cited by 38 publications

(9 citation statements)

References 11 publications

(11 reference statements)

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“…In view of the above assessment, in the next section, several optimization approaches for CCCs optimal design will be discussed in detail. In the work by Kirchheim et al [29], the researchers performed a transient thermal analysis in Moldex 3D software to evaluate the design of the CCCs, particularly filling and packing simulation. They have concluded that the heat distribution is more homogeneous and that a 24% reduction in cycle time can be achieved.…”

Section: Thermo-mechanical Modelsmentioning

confidence: 99%

Optimization to Assist Design and Analysis of Temperature Control Strategies for Injection Molding—A Review

et al. 2022

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Injection molding (IM) is the most widespread and economical way to obtain high-quality plastic components. The process depends, however, to a great extent, on the quality and efficiency of the injection molding tools. Given the nature of the IM process, the temperature control system (TCS), its design, and its efficiency are of utmost importance for achieving the highest possible quality of plastic parts in the shortest possible time. For that reason, the implementation of additive manufacturing (AM) in novel IM temperature control strategies has gained considerable interest in academia and industry over the years. Conformal cooling channels (CCCs) are TCSs that have already demonstrated great potential when compared to conventional gun-drilling systems. Nevertheless, despite the recent advances, the design of these systems is still an open field of study and requires additional research in both aspects deemed as critical: thermo-mechanical models and the application of optimization techniques. This review paper tackles all the relevant, available papers on this topic, highlighting thermo-mechanical models developed by TCS designers and the optimization techniques used. The articles were thoroughly analyzed, and key points on the design of new TCS and new opportunities were identified.

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Section: Thermo-mechanical Modelsmentioning

confidence: 99%

Optimization to Assist Design and Analysis of Temperature Control Strategies for Injection Molding—A Review

et al. 2022

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“…Cooling strategy Fig. 1 Knowledge areas for gears with internal cooling channels ufacturing of force-flow-optimised lightweight structures, e.g., those used in toolmaking, the integration of internal channel structures enables new opportunities for optimisation [5,6]. In particular, the design of injection moulds utilises conformal cooling for process optimisation [7].…”

Section: Functional Integrationmentioning

confidence: 99%

“…Fig 6. Technical data of the FZG type A gear with internal cooling channels; pinion gear and gear pair…”

mentioning

confidence: 99%

Increasing the safety against scuffing of additive manufactured gear wheels by internal cooling channels

Dennig

Zumofen

Stierli³

et al. 2021

Forsch Ingenieurwes

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The layer-by-layer principle of the additive manufacturing (AM) technology of Laser-Powder-Bed-Fusion (LPBF) creates new opportunities in the design and manufacturing of efficient gear components. For example, integrating a cooling system can increase the safety against scuffing or reduce the amount of required lubrication and thus the splashing losses. Quenched and tempered steels or case-hardened steels are commonly used in the fabrication of gear components. However, the availability of these alloys for LPBF processing is still limited. The development of suitable LPBF metal gears (with a Gear Research Centre (FZG) type A geometry) out of quenched and tempered 30CrNiMo8 steel with internal cooling channels shows the possibility of significantly increasing the safety factor against scuffing. This work includes the development of a suitable cooling strategy, material development, the setup of a suitable test infrastructure and the analysis of the LPBF gears tested for scuffing.

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“…This fact causes manufacturers to increase the use of injection molded parts due to their recyclability, durability, vibration control, strength, etc. [ 6 , 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

et al. 2023

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Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric features, and this occurs with topologies of great length and slenderness with high changes in thickness. These features are, in these special geometries, impossible to manufacture with traditional technologies to meet the dimensional and sustainable requirements of the industry. This paper presents an innovative green conformal cooling system that is specifically designed for parts with slender geometric shapes that are highly susceptible to warping. Additionally, the work presented by the authors investigates the importance of using highly conductive inserts made of steel alloys in combination with the use of additively manufactured conformal channels for reducing influential parameters, such as warpage, cooling time, and residual stresses in the complex manufacturing of long and slender parts. The results of this real industrial case study indicated that the use of conformal cooling layouts decreased the cycle time by 175.1 s—66% below the current cooling time; the temperature gradient by 78.5%—specifically, 18.16 ºC; the residual stress by 39.78 MPa—or 81.88 %; and the warpage by 6.9 mm—or 90.5%. In this way, it was possible to achieve a final warping in the complex geometry studied of 0.72 mm, which was under the maximum value required at the industrial level of 1 mm. The resulting values obtained by the researchers present a turning point from which the manufacturing and sustainability in the injection molding of said plastic geometries is possible, and they take into account that the geometric manufacturing features analyzed will present a great demand in the coming years in the auto parts manufacturing industry.

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Dynamic conformal cooling improves injection molding

Cited by 38 publications

References 11 publications

Optimization to Assist Design and Analysis of Temperature Control Strategies for Injection Molding—A Review

Optimization to Assist Design and Analysis of Temperature Control Strategies for Injection Molding—A Review

Increasing the safety against scuffing of additive manufactured gear wheels by internal cooling channels

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

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