Optimization of conformal cooling channels with array of baffles for plastic injection mold

Abstract

Cooling system has an important role in the injection molding process in terms of not only productivity and quality, but also mold-making cost. In this paper, a conformal cooling channel with an array of baffles is proposed for obtaining uniform cooling over the entire free-form surface of molded parts. A new algorithm for calculating temperature distribution through molding thickness, mold surface temperature and cooling time was presented. The relation among cooling channels' configuration, process parameters, mold material, molding thickness and temperature distribution in the mold for a given polymer is expressed by a system of approximate equations. This relation was established by the design of experiment and response surface methodology based on an adequate physical-mathematical model, finite difference method and numerical simulation. By applying this approximate mathematical relation, the optimization process for obtaining target mold temperature, uniform temperature distribution and minimizing the cooling time becomes more effective. Two case studies were carried out to test and validate the proposed method. The results show that present approach improves the cooling performance and facilitates the mold design process in comparison to the trial-and-error simulation-based method.

Milled Groove Square Shape Conformal Cooling Channels in Injection Moulding Process

“…Besides, some researchers focused on how to design and fabricate conformal cooling channels to achieve the effective cooling channels [2,5,[10][11][12]. In recent years, researchers have started to focus on conformal cooling channels on hard tooling when designers realized the use of conformal cooling channels was better than conventional cooling channels.…”

“…A good design of a cooling channels system has the ability to improve productivity without compromising quality. The efficient cooling channels result in a uniform thermal distribution as a non-uniform thermal distribution will cause longer cycle time, differential shrinkage and warpage defects on the molded parts [5]. Thus, conformal cooling channels offer a practical solution to ensure that the layout of cooling channels follows the shape of molded parts with the proximity between the cooling channels and the mold surface is maintained.…”

Optimization of the plastic injection molding process using the Taguchi method, RSM, and hybrid GA-PSO

“…Kurtaran and Erzurumlu [16] further integrated DOE, RSM, and GA to obtain the optimal thin plastic warpage parameters and utilized ANOVA to find the more important factors, as well as combining the RSM and GA to find the optimal process parameters. Park and Dang [17] combined DOE and RSM together with ANOVA and numerical simulations to conduct optimization experiments. Similarly, Sun et al [18] utilized simulation software combined with RSM and GA to find the optimal injection molding parameters.…”

Research on optimization design of conformal cooling channels in hot stamping tool based on response surface methodology and multi-objective optimization

“…Xu et al presented a systematic approach for conformal design which is evaluated by five criteria, including transient heat transfer condition, maximum distance from the mould surface to cooling channel, pressure drop, temperature drop and mould strength [8]. Park and Dang designed a cooling layout with an array of baffles to achieve the conformal characteristics [9]. Hu et al raised four types of conformal designs and the longitudinal conformal cooling channel was proved as the optimal cooling design when inlet mass flow rate was large [10].…”