Efficiency of Conformal Cooling Channels Inserts for Extrusion Dies

Pelaccia, Riccardo; Negozio, Marco; Donati, Lorenzo; Reggiani, Barbara; Tomesani, Luca

doi:10.1016/j.promfg.2020.04.181

Cited by 9 publications

(6 citation statements)

References 9 publications

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“…If the parameters used in the design are no longer within the experimental data range, the guideline chart will be rendered impractical. Pipeline scanning method are the most widely used approach to design and optimize the cooling channels [13][14][15][16][17][18] . The basic idea of this method is to scan the specified section along the trajectory line to form cooling channels, and trajectory lines are the centerline of the cooling channels.…”

Section: Related Workmentioning

confidence: 99%

Research on Automatic Generation Technology of Cooling Channels for Injection Mold of Automotive Interior Door Panel

Wang,

2024

Preprint

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The automotive interior door panel is an important injection molded part in automotive interiors, and a good cooling system is crucial to ensure its molding quality. In fact, due to the complex structure of the automotive interior door panel mold, designing hundreds of cooling channels inside it is often a very tedious and time-consuming task. For a long time, designers can only rely on basic modeling tools and build cooling channels through a large number of interactive operations, which will require a lot of time and effort. To solve this problem, this paper proposes an automatic generation method for cooling channels from a practical perspective based on the basic structural characteristics of cooling channels and the basic rules of mold cooling system design. The basic idea is to first offset adjacent boundary lines on the side of the mold core, and generate a series of scan lines starting from the intersection of the offset lines; Then generate channel entities with specified channel diameters along the scanning line, and perform interference checks on all generated channels; Finally, optimize the positions of all channels and remove unsuitable ones. Experimental results show that this method is simple and practical, and can quickly generate cooling channels that meet the requirements, greatly saving design time, reducing design errors, and improving design efficiency.

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Section: Related Workmentioning

confidence: 99%

Research on Automatic Generation Technology of Cooling Channels for Injection Mold of Automotive Interior Door Panel

Wang,

2024

Preprint

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“…The 1D modelling of the cooling channel reduces the calculation of the thermal and fluid dynamics variables to the middle line of the cooling path but allows to set the geometric characteristic of the channel section as well as the concentrated pressure drop within the channel. In addition, the heat transfer coefficient is not considered constant along the cooling path [13][14] thus suggesting a reliable evaluation of the cooling efficiency of the channel design combined with a substantial reducing of computational time. In Fig.…”

Section: Experimental Campaign Experimental Campaignmentioning

confidence: 99%

“…The finite element modelling (FEM) of hot aluminum extrusion process is a yet well-consolidated practice to predict the main output parameters in terms of thermal gradient, extrusion load and potential profile and tool defects [9][10][11][12]; however, only few works deal with the modelling of cooling. In this context, aim of this work is further assessing the potentiality of a 3D numerical model of the extrusion process integrated with a 1D model of the cooling channel, proposed by the authors in a previous work [13], against a more complex industrial case study. The capabilities of the numerical re-design of the channel are also shown with the aim to obtain during the die design stage an optimal cooling solution in terms of balanced thermal field and nitrogen consuming.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Analysis and optimization of cooling channels performances for industrial extrusion dies

Pelacci¹,

Negozio²,

Reggiani³

et al. 2021

Esaform 2021

Self Cite

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Liquid nitrogen cooling is widely used in the extrusion industrial practice in order to increase the production rate, to reduce the die temperature and to avoid defects on the profile exit surfaces resulting from an excessive heating. However, the efficiency of the cooling is deeply affected by position and design of the liquid nitrogen channel so that numerical modelling is gaining an increasing industrial interest in relation to the possibility offered to optimize the channel design without expensive and time-consuming experimental trials. In this work, a numerical FE model developed within COMSOL Multiphysics® is proposed and validated against experimental trials performed in industrial environment. The model combines the 3D simulation of the extrusion process with a 1D model of the cooling channel thus allowing the testing of a number of different solutions at the die design stage. The global aim of this work is the assessment of the liquid nitrogen cooling efficiency in the extrusion of an industrial aluminum profile and the proof of the potentials offered by numerical models to get an optimized channel design in terms of cooling efficiency, die thermal balancing and reduction of liquid nitrogen consumption.

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“…28 A platform for testing the liquid nitrogen cooling for multi-die design was proposed. 29 To provide extruders and die manufacturers with a numerical tool particularly for the thermal distributions of dies, a FEM model for the extrusion process with the liquid nitrogen cooling system was developed. 30 A numerical model of AA6060 extrusion process was carried out to predict and optimize the nitrogen cooling effect in the die.…”

Section: Introductionmentioning

confidence: 99%

“…The capability of nitrogen cooling within a conformal channel was experimentally and numerically assessed, for the extrusion of AA6063 aluminium and ZM21 magnesium alloys 28 . A platform for testing the liquid nitrogen cooling for multi‐die design was proposed 29 . To provide extruders and die manufacturers with a numerical tool particularly for the thermal distributions of dies, a FEM model for the extrusion process with the liquid nitrogen cooling system was developed 30 .…”

Section: Introductionmentioning

confidence: 99%

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

Chen

Jiang

et al. 2022

Energy Science & Engineering

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Aluminium production needs the most energy‐intensive technologies among all the metal processing sectors. During the process of aluminium profile extrusion, the whole production line needs bulk electricity, and the mold inside the extrusion equipment needs robust cold energy for rapid cooling of the metal surface. This paper presents a new combo‐transmission that can simultaneously deliver cold energy together with electricity to the aluminium profile extrusion line. Thanks to the superiority of virtually zero loss and compact size, the powerful superconducting cable is used to replace the conventional copper cable. The entire superconducting cable assembly is fully installed into a cryogenic pipeline and cooled by liquid nitrogen at 77 K. In addition to keeping a favourable cryogenic environment for the superconducting cable, liquid nitrogen can also provide a large amount of cold energy for cooling the metal surface. For a typical 100 MN aluminium extrusion production line, the design and optimization of 10 kA class superconducting cable with the pipeline cooling system for aluminium production are presented in detail. The simulation results and comparisons show that the total energy loss of superconducting transmission is about 46% of conventional copper cable, and the energy saved in a year can be up to about 240.6 MWh. Moreover, the net profit increases almost linearly along with the increases of the extrusion speed when the liquid nitrogen cooling is applied to the 100 MN production line. For the case of 23% increase in extrusion speed, the net profit can be up to 1.48 M$ in a year. Overall, the novel design, technical evaluation, and economic analysis of the combo‐transmission system (cold energy + electricity) can provide a promising solution for future high‐dense aluminium production sectors.

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Efficiency of Conformal Cooling Channels Inserts for Extrusion Dies

Cited by 9 publications

References 9 publications

Research on Automatic Generation Technology of Cooling Channels for Injection Mold of Automotive Interior Door Panel

Research on Automatic Generation Technology of Cooling Channels for Injection Mold of Automotive Interior Door Panel

Analysis and optimization of cooling channels performances for industrial extrusion dies

A novel combo‐transmission system of cold energy and electricity for aluminium profile production: Using liquid nitrogen and superconductor technologies

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