Experimental analysis of conformal cooling in SLM produced injection moulds: Effects on process and product quality

Evens, Tim; Six, Wim; Keyzer, Jozefien De; Desplentere, Frederik; Bael, Albert Van

doi:10.1063/1.5084861

Cited by 22 publications

(17 citation statements)

References 4 publications

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“…In addition, a high relative density of 99.95% was determined. Specimens in the as-built condition show an Archimedean density of 7.850 ± 0.003 g/cm 3 . Accordingly, it was proven that the L-PBF process parameters (Table 2) were suitable for crack-free processing of the hot-work tool steel AISI H10 powder to high-density specimens.…”

Section: L-pbf Processmentioning

confidence: 99%

“…However, the application of such channels leads to new challenges in terms of manufacturing techniques. The laser powder bed fusion (L-PBF) process allows the production of complex internal channel geometries and was used in this study [3]. Another challenge is the stability of the forging dies, which is reduced by internal cooling channels.…”

Section: Introductionmentioning

confidence: 99%

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Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

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Internal die cooling during forging can reduce thermal loads, counteracting surface softening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In this study, hybrid forging dies were developed combining conventional manufacturing processes and laser powder bed fusion (L-PBF) achieving conformal cooling channels. A characterisation of the used hot-work tool steel’s AISI H10 powder material was carried out in order to determine suitable parameters for L-PBF processing and heat treatment parameters. Additionally, the mechanical properties of L-PBF-processed AISI H10 specimens were investigated. Furthermore, the influence of different internal cooling channels regarding a possible structural weakening of the die were analysed by means of a finite element method (FEM) applied to a hot-forging process. The numerical results indicated that the developed forging dies withstood the mechanical loads during a forging process. However, during the investigation a large dependency between the resulting stresses and the chosen parameters were observed. By choosing the best combination of parameters, a reduction of the equivalent stress by 1000 MPa can be achieved. Finally, a prototype of the hybrid-forging dies featuring the most promising cooling channel geometry was manufactured.

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Section: L-pbf Processmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Behrens

Huskic

Rosenbusch

et al. 2022

Metals

View full text Add to dashboard Cite

show abstract

“…Furthermore, the design freedom of L-PBF can enable the manufacture of different cross-sections with varying profiles and surface finish. To date, many studies on the introduction of conformal cooling channels in injection molds have been carried out [13][14][15][16]. Successful design of conformal cooling channels can be achieved by considering the following criteria: a transient heat transfer condition, which dictates a maximum distance from the mold surface to cooling channel; pressure and temperature drop along the flow channel, and the strength of the mold [17].…”

Section: Conformal Coolingmentioning

confidence: 99%

Dynamic conformal cooling improves injection molding

Kirchheim

Katrodiya

Zumofen

et al. 2021

Int J Adv Manuf Technol

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To achieve a certain visual quality or acceptable surface appearance in injection-molded components, a higher mold surface temperature is needed. In order to achieve this, injection molds can be dynamically tempered by integrating an active heating and cooling process inside the mold halves. This heating and cooling of the mold halves becomes more efficient when the temperature change occurs closer to the mold surface. Complex channels that carry cold or hot liquids can be manufactured close to the mold surface by using the layer by layer principle of additive manufacturing. Laser powder bed fusion (L-PBF), as an additive manufacturing process, has special advantages; in particular, so-called hybrid tools can be manufactured. For example, complex tool inserts with conformal cooling channels can be additively built on simple, machined baseplates. This paper outlines the thermal simulation carried out to optimize the injection molding process by use of dynamic conformal cooling. Based on the results of this simulation, a mold with conformal cooling channels was designed and additively manufactured in maraging steel (1.2709) and then experimentally tested.

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“…In many cases, the conformal geometry of cooling channels eliminates 90° connections of the drilled channels. Such perpendicular connections cause sharp drops in cooling liquid pressure, and their elimination increases the efficiency of the cooling [ 8 , 9 ]. The rules for designing traditional cooling channels are well-known; they come down to determining each channel’s diameter, the distance of each channel’s surface from the surface of the mould cavity, and the distances between its adjacent channels.…”

Section: Introductionmentioning

confidence: 99%

Shape-Dependent Strength of Al Si9Cu3FeZn Die-Cast Alloy in Impact Zone of Conformal Cooling Core

2022

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This article presents the results of shape-dependent strength analyses in die-castings from traditional (straight-drilled) and conformal core-cooling moulds. Cores with a traditional cooling layout were made of H13 steel using machining, and the working sections of the conformal cores were made using the selective laser melting method (SLM). Two series of casts were produced in the same mould. For Series A, the mould was fitted with traditional cooling cores, and for Series B, the same mould was fitted with conformal ones. The cast specimens were subjected to two weeks of natural ageing. The strength testing of the casts determined the levels of the destructive forces. The destructive forces in the core-cooling impact zones were approximately 28% higher in the B samples than they were in the A samples. The impact of the alloy’s porosity, density, and microstructure on the strengths of the casts was demonstrated. The alloy densities in the central (broken-off) fragments of the casts from Series A were 2.6646 g/cm3; these were 2.6791 g/cm3 in the cases of casts from Series B. The values of the secondary dendrite arm space (SDAS) ranged from 6 to 13 μm in the analysed cross-section of the set of the A casts, and between 3 and 12 μm in the same zone of the set of the B casts. The results of the experimental determinations of the casts porosity levels and SDAS parameters were compared with the results of numerical simulations that were carried out in ProCAST software.

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Experimental analysis of conformal cooling in SLM produced injection moulds: Effects on process and product quality

Cited by 22 publications

References 4 publications

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Design, Characterisation and Numerical Investigations of Additively Manufactured H10 Hybrid-Forging Dies with Conformal Cooling Channels

Dynamic conformal cooling improves injection molding

Shape-Dependent Strength of Al Si9Cu3FeZn Die-Cast Alloy in Impact Zone of Conformal Cooling Core

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