Thermo-mechanical Design Optimization of Conformal Cooling Channels using Design of Experiments Approach

Jahan, Suchana A.; Wu, Tong; Zhang, Yi; Zhang, Jing; Tovar, Andrés; El-Mounayri, Hazim

doi:10.1016/j.promfg.2017.07.078

Cited by 61 publications

(36 citation statements)

References 28 publications

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“…After we have all 4 molds, we will test them both experimentally and numerically. From previous studies, it is known to the authors that the experimental and numerical results do not match well [2][3][4][5][6][7]. There is about 5-10% difference between them.…”

Section: Design Of Experimentsmentioning

confidence: 92%

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

Jahan

El-Mounayri

Tovar

et al. 2018

Mechanics of Additive and Advanced Manufacturing, Volume 8

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Additive Manufacturing(AM), 3D printing, rapid prototyping, or rapid tooling refer to a range of technologies that are capable of translating virtual CAD model data into physical model. It is executed in growing number of applications nowadays. A wide range of materials are currently being used to produce consumer products and production tools. AM has brought in revolutionary changes in traditional manufacturing practices. Yet, there are certain drawbacks that hinder its advancement at mass manufacturing. High cost associated with AM is one of them. Using 3D printed tooling can provide long-time cost effectiveness and better product quality. Additively manufactured injection molds can increase the cooling performance, reduce production cycle time, and improve surface finish and part quality of the final plastic product. Yet, manufacturers are still not using the printed molds for industrial mass production. Numerical analysis can provide approximation of such improved performance, but, factual experimental results are necessary to satisfy performance criteria of molds to justify the large investment into tooling for existing industries. In this research work, a desktop injection molding machine is used to evaluate performance of 3D printed molds to develop a cost and performance analysis tool. It serves as a baseline to predict the performance of molds in real-time mass manufacturing of consumer products. The analysis describes how appropriate the estimation can be from any simulation study of molds, how much the scaling down of tool and molding system can affect the prediction of actual performance, what correction factors can be used for better approximation of performance matrices. Several "scaled down" prototypes of injection molds have been used. They have design variations as: with or without cooling system, conformal or straight cooling channels, solid or lattice matrix, and metal or tough resin as the mold material. The molds are printed in in-house printing machines and can also be printed online with limited charges. This also provides an excellent demonstration of using inexpensive material and manufacturing process, such as resin to estimate the performance of highly expensive 3D printed stainless steel molds. The work encompasses a framework to reduce overall cost of implementing AM, by lowering time and monetary expenses during the research and development, and prototyping phases.

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Section: Design Of Experimentsmentioning

confidence: 92%

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

Jahan

El-Mounayri

Tovar

et al. 2018

Mechanics of Additive and Advanced Manufacturing, Volume 8

Self Cite

View full text Add to dashboard Cite

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“…In previous studies by this research group [37][38][39][40][41][42][43][44][45], the numerical analysis and design decisions regarding the performance of conformal cooling channels in injection molds were conducted with the single consideration of fast cooling. In addition, static structural analysis was conducted to ensure the structural stability of the mold cores and cavities with conformal channels.…”

Section: Thermomechanical Optimizationmentioning

confidence: 99%

“…This is the principal motivating objective of this research effort. The effort of identifying a design technique for optimal conformal cooling channels in injection molds has been initiated in recent years by Jahan and Wu et al [37][38][39][40][41][42][43]. This current paper provides a guideline for the mold designers to design their injection molds with the conformal cooling channels that would enable them to obtain the most benefit in business.…”

Section: Introductionmentioning

confidence: 99%

A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Jahan

El-Mounayri

2018

Applied Sciences

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Plastic injection molding is a versatile process, and a major part of the present plastic manufacturing industry. The traditional die design is limited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermomechanical) performance. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum conformal channels based on thermomechanical performance are not found in the literature. This paper proposes a design methodology to generate optimized design configurations of such channels in plastic injection molds. The design of experiments (DOEs) technique is used to study the effect of the critical design parameters of conformal channels, as well as their cross-section geometries. In addition, designs for the “best” thermomechanical performance are identified. Finally, guidelines for selecting optimum design solutions given the plastic part thickness are provided.

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“…Optimization strategies involving the use of various algorithms for designing the shape and layout of cooling channels have been frequently discussed in the literature [12][13][14]. Moreover, many studies have used DOE to set optimal process parameters for injection molding [15,16].…”

Section: Introductionmentioning

confidence: 99%

Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

Chung

2019

Applied Sciences

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Plastic lenses are light and can be mass-produced. Large-diameter aspheric plastic lenses play a substantial role in the optical industry. Injection molding is a popular technology for plastic optical manufacturing because it can achieve a high production rate. Highly efficient cooling channels are required for obtaining a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, highly efficient three-dimensional spiral channels can be realized for conformal cooling technique. However, the design of conformal cooling channels is very complex and requires optimization analyses. In this study, finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels. According to the simulation results, the use of conformal cooling channels can reduce the surface temperature difference of the melt, ejection time, and warpage. Moreover, the optimal process parameters (such as melt temperature, mold temperature, filling time, and packing time) obtained from the design of experiments improved the fringe pattern and eliminated the local variation of birefringence. Thus, this study indicates how the optical properties of plastic lenses can be improved. The major contribution of present proposed methods can be applied to a mold core containing the conformal cooling channels by metal additive manufacturing.

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Thermo-mechanical Design Optimization of Conformal Cooling Channels using Design of Experiments Approach

Cited by 61 publications

References 28 publications

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

A Framework for Estimating Mold Performance Using Experimental and Numerical Analysis of Injection Mold Tooling Prototypes

A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

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