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

Abstract

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.

Optimizing heat source distribution in sintering molds: Integrating response surface model with sequential quadratic programming

“…This mold incorporates a heating system consisting of multiple sintering cavities positioned on the surface and 11 heating rods. To enhance cooling efficiency in industrial applications, the heating system is designed with S-shaped water-cooling channels [ 20 , 21 ]. The layout of heating rods and their power density configuration are critical in achieving uniform temperature distribution.…”

The constant/variable kinematics adjustment of the crosshead and the mold’s stability management in injection molding

“…The magnitude of clamping force generated by the toggle clamping mechanism can affect the quality of plastic parts [10][11][12][13][14][15][16] as well as the mold's service life [17][18][19]. However, excessive force amplification harms the clamping mechanism, the mold, and the product's quality.…”