Thermal and Design Sensitivity Analyses for Cooling System of Injection Mold, Part 1: Thermal Analysis

Park, S. J.; Kwon, Tai Hun

doi:10.1115/1.2830126

Cited by 37 publications

(17 citation statements)

References 5 publications

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“…115 The calculated sensitivities are then used to optimize the position of linear cooling channels for simple mold cavity shapes. 116 Later, Lam and Seow 117 presented a new method for flow path generation using the hill-climbing algorithm. It overcomes the difficulties of the straight flow path assumption by deriving the flow paths from the fill pattern of the cavity.…”

Section: Application Of Numerical Simulation Approachmentioning

confidence: 99%

Modeling and Optimization of the Injection‐Molding Process: A Review

et al. 2016

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ABSTRACT:The purpose of this article is to review the research done in the field of mathematical modeling and optimization of the injection-molding (IM) process. Various papers related to the mathematical description of the filling, postfilling, and plasticating phases of the IM process were assessed, and some recent advances on the IM field are described. In addition, research devoted to the optimization of the IM process based on various techniques is also discussed. These optimization techniques include design of experiments, artificial neural networks, and evolutionary algorithms. The strengths and weaknesses of each approach were discussed. Finally, this paper also discusses the optimization research performed in the IM process regarding some of the specific features associated with the processes such as runner system and cooling channel configurations, process conditions, gate location, and cavity pressure balancing. C

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Section: Application Of Numerical Simulation Approachmentioning

confidence: 99%

Modeling and Optimization of the Injection‐Molding Process: A Review

et al. 2016

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“…The first group focuses on how to optimize the configuration of the cooling system in terms of shape, size and location of cooling lines. [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15] The second group investigates the way to build the cooling layout namely conformal cooling channels that conform to the mold cavity surface and examines the effectiveness of this cooling system. Solid free-from fabrication (SFF) or rapid prototype (RP) techniques have been proposed to build this complex cooling system.…”

Section: Introductionmentioning

confidence: 99%

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

Park

Dang

2010

Int. J. Precis. Eng. Manuf.

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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.

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“…Several attempts have also been made to optimize the parameters in feeding [4][5][6][7], cooling [2,8,9], and ejection [10]. These attempts were based on maximizing the flowability of molten material during the molding process by using empirical relationships between the product and mold design parameters.…”

Section: Current Researchmentioning

confidence: 99%

Minimizing manufacturing costs for thin injection molded plastic components

Chu

Mok

2004

Int J Adv Manuf Technol

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Minimizing the cost of manufacturing a plastic component is very important in the highly competitive plastic injection molding industry. The current approach of R&D work focuses on optimizing the dimensions of the plastic component, particularly in reducing the thickness of the component during product design, the first phase of manufacturing, in order to minimize the manufacturing cost. This approach treats the component dimensions established in the product design phase as the given input, and uses optimization techniques to reduce the manufacturing cost of mold design and molding for producing the component. In most cases, the current approach provides the correct solution for minimizing the manufacturing cost. However, when the approach is applied to a thin component, typically when miniaturizing products, it has problems finding the true minimum manufacturing cost. This paper analyses the shortcomings of the current approach for handling thin plastic components and proposes a method to overcome them. A worked example is used to illustrate the problems and compare the differences when using the current approach and the new method proposed in the paper.Keywords Miniaturization of plastic parts · Minimization of manufacturing · Plastic part design and manufacturing cost Nomenclature B Plastic material dependent constant C l Material cost for single cavity insert = $ 557 Cs Specific heat of polymer = 2.5 kJ/kg K C w Labor cost of mold making machine = $ 2.0/h D 1 Diameter of hydraulic cylinder of molding machine D 2 Diameter of hydraulic cylinder of molding machine D R The thickness of gate H r The thickness of the rectangular channel i m Latent heat of fusion of PP = 130 kJ/kg L G The length of gate = 0.5-1.3 L C The length of circular channel L r The length of rectangular channel m(T ) the consistency index m 1/Poisson ratio of PP = 0.35 n p Plastic material constant, Q The volume flow rate Q r The volume flow rate inside the rectangular channel Q runner The volume flow rate inside the runner Q C The volume flow rate inside the circular channel R C The radius of the circular channel S Distance of piston movement t Loading time = 31 536 000 s t CC Time for making single cavity mold insert = 15 h t dc Dry cycle time = 16.5 s t ej Ejection time = 0.009 s t in Injection time = 0.5 s T b Plastic material dependent constants T E Demolding temperature of PP = 70 • C T M Melt temperature of PP = 190 • C W GThe width of gate W r

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Thermal and Design Sensitivity Analyses for Cooling System of Injection Mold, Part 1: Thermal Analysis

Cited by 37 publications

References 5 publications

Modeling and Optimization of the Injection‐Molding Process: A Review

Modeling and Optimization of the Injection‐Molding Process: A Review

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

Minimizing manufacturing costs for thin injection molded plastic components

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