A computational model for the cooling phase of injection moulding

Smith, Andrew G.; Wrobel, L.C.; McCalla, B. A.; Allan, Peter; Hornsby, Peter

doi:10.1016/j.jmatprotec.2007.05.018

Cited by 11 publications

(9 citation statements)

References 4 publications

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“…16 In fact, the thermal properties of polymers are timedependent, and this characteristic significantly influences the analysis results. 24,25 Three-dimensional CAE simulation software tackles this problem very well, so the precise result can be obtained in comparison with applying the analytical method with constant thermal properties. Moreover, the ability of coupling with filling and packing computation, warpage and residual stress analysis as well as convenient graphical visualization are also the strong points of 3D CAE simulation.…”

Section: Systematic Procedures For Optimizationmentioning

confidence: 99%

Design of U-shape milled groove conformal cooling channels for plastic injection mold

Dang

Park

2011

Int. J. Precis. Eng. Manuf.

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Besides the solid free-form fabrication technology, milling operation is an alternative applicable method to make complex cooling channels conform to the surface of the mold cavity. This paper presents the U-shape milled groove conformal cooling channels and proposes the design optimization process in order to obtain an optimal cooling channels' configuration and target mold temperature. The relation between the cycle averaged thermal behavior of the mold cavity and the two-dimensional configuration of cooling channels was first investigated thoroughly by an analytical method. Design of experiment and 2D simulation were done to obtain the mold wall temperature and to check the feasibility of the analytical method. The optimization process of the free-form conformal cooling channels is based on the combination of both analytical method and 3D CAE simulation. The analytical step relies on explicit mathematic formulas, so it can approach the neighboring optimal solution quickly. Subsequently, the three-dimensional heat transfer simulation is applied to fine-tune the optimization results. A case study for a plastic car fender was investigated to verify the feasibility of the proposed method. The results show that conformal cooling channel gives a uniform cooling, reducing the cooling time and increasing the molded part's quality with less effort of plastic designers and high computational efficiency.

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Section: Systematic Procedures For Optimizationmentioning

confidence: 99%

Design of U-shape milled groove conformal cooling channels for plastic injection mold

Dang

Park

2011

Int. J. Precis. Eng. Manuf.

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“…TCR is the function of a gap, roughness of contact surface, time and process parameters. The values of TCR are very different, 29,34,[40][41][42][43][44][45] and they are often obtained by experiment. In this study, HTC is set to 10,000 W/m 2°C at the beginning of cooling stage; this value decreases exponentially to 2000 W/m 2°C after one tenth of total cooling time and keep constant during the time left.…”

Section: Physical-mathematical Model and Numerical Solutionmentioning

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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“…TCR is the function of a gap, roughness of contact surface, time, and process parameters. The values of TCR are very different (Yu et al, 1990;C-MOLD, 1997;Delaunay et al, 2000;Sridhar & Narh, 2000;Le Goff et al, 2005;Dawson et al, 2008;Hioe et al, 2008;Smith et al, 2008), and they are often obtained by experiment.…”

Section: Physical and Mathematical Modeling Of Cooling Channelsmentioning

confidence: 99%

Design and simulation-based optimization of cooling channels for plastic injection mold

Park¹,

Dang²

2012

New Technologies - Trends, Innovations and Research

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A computational model for the cooling phase of injection moulding

Cited by 11 publications

References 4 publications

Design of U-shape milled groove conformal cooling channels for plastic injection mold

Design of U-shape milled groove conformal cooling channels for plastic injection mold

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

Design and simulation-based optimization of cooling channels for plastic injection mold

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