A new conformal cooling lattice design procedure for injection molding applications based on expert algorithms

Mercado-Colmenero, Jorge Manuel; Martín-Doñate, Cristina; Rodriguez-Santiago, Moisés; Moral-Pulido, Francisco; Rubio-Paramio, Miguel Angel

doi:10.1007/s00170-018-03235-3

Cited by 49 publications

(20 citation statements)

References 28 publications

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“…Furthermore, the design freedom of L-PBF can enable the manufacture of different cross-sections with varying profiles and surface finish. To date, many studies on the introduction of conformal cooling channels in injection molds have been carried out [13][14][15][16]. Successful design of conformal cooling channels can be achieved by considering the following criteria: a transient heat transfer condition, which dictates a maximum distance from the mold surface to cooling channel; pressure and temperature drop along the flow channel, and the strength of the mold [17].…”

Section: Conformal Coolingmentioning

confidence: 99%

Dynamic conformal cooling improves injection molding

Kirchheim

Katrodiya

Zumofen

et al. 2021

Int J Adv Manuf Technol

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To achieve a certain visual quality or acceptable surface appearance in injection-molded components, a higher mold surface temperature is needed. In order to achieve this, injection molds can be dynamically tempered by integrating an active heating and cooling process inside the mold halves. This heating and cooling of the mold halves becomes more efficient when the temperature change occurs closer to the mold surface. Complex channels that carry cold or hot liquids can be manufactured close to the mold surface by using the layer by layer principle of additive manufacturing. Laser powder bed fusion (L-PBF), as an additive manufacturing process, has special advantages; in particular, so-called hybrid tools can be manufactured. For example, complex tool inserts with conformal cooling channels can be additively built on simple, machined baseplates. This paper outlines the thermal simulation carried out to optimize the injection molding process by use of dynamic conformal cooling. Based on the results of this simulation, a mold with conformal cooling channels was designed and additively manufactured in maraging steel (1.2709) and then experimentally tested.

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Section: Conformal Coolingmentioning

confidence: 99%

Dynamic conformal cooling improves injection molding

Kirchheim

Katrodiya

Zumofen

et al. 2021

Int J Adv Manuf Technol

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“…To resolve these issues, Tang et al [43] proposed a general design method of conformal porous structure for injection mold cooling that can achieve better cooling performance by reducing the maximum average mold temperature and the pressure drop. More recently, Mercado et al [44] proposed a new layout for a conformal cooling system with the surface of a parametric lattice. The parameters of the cooling channels, such as the diameter of the incoming lattice channels, are automatically sized requiring as input only information of the material and the part topology.…”

Section: Background and Related Workmentioning

confidence: 99%

“…The parameters of the cooling channels, such as the diameter of the incoming lattice channels, are automatically sized requiring as input only information of the material and the part topology. Even so, the topologies of the lattice arrangements [39][40][41][42][43][44] could originate too much turbulence and pressure drops in the coolant flow as it advances through the scaffolds.…”

Section: Background and Related Workmentioning

confidence: 99%

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

et al. 2020

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This paper presents a new method for the automated design of the conformal cooling system for injection molding technology based on a discrete multidimensional model of the plastic part. The algorithm surpasses the current state of the art since it uses as input variables firstly the discrete map of temperatures of the melt plastic flow at the end of the filling phase, and secondly a set of geometrical parameters extracted from the discrete mesh together with technological and functional requirements of cooling in injection molds. In the first phase, the algorithm groups and classifies the discrete temperature of the nodes at the end of the filling phase in geometrical areas called temperature clusters. The topological and rheological information of the clusters along with the geometrical and manufacturing information of the surface mesh remains stored in a multidimensional discrete model of the plastic part. Taking advantage of using genetic evolutionary algorithms and by applying a physical model linked to the cluster specifications the proposed algorithm automatically designs and dimensions all the parameters required for the conformal cooling system. The method presented improves on any conventional cooling system design model since the cooling times obtained are analogous to the cooling times of analytical models, including boundary conditions and ideal solutions not exceeding 5% of relative error in the cases analyzed. The final quality of the plastic parts after the cooling phase meets the minimum criteria and requirements established by the injection industry. As an additional advantage the proposed algorithm allows the validation and dimensioning of the injection mold cooling system automatically, without requiring experienced mold designers with extensive skills in manual computing.

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“…Advanced technologies commonly used in the industrial manufacturing sector [ 14 ], are being progressively transferred to the field of architecture and construction. The particularities of the construction field constitute a challenge in the process of adapting technologies from the industrial area.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analysis for the Mechanical Characterization of PETG Polymers Manufactured with FDM Technology under Pure Uniaxial Compression Stress States for Architectural Applications

et al. 2020

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This paper presents the numerical and experimental analysis performed on the polymeric material Polyethylene Terephthalate Glycol (PETG) manufactured with Fused Deposition Modeling Technology (FDM) technology, aiming at obtaining its mechanical characterization under uniaxial compression loads. Firstly, with the objective of evaluating the printing direction that poses a greater mechanical strength, eighteen test specimens were manufactured and analyzed according to the requirements of the ISO-604 standards. After that, a second experimental test analyzed the mechanical behavior of an innovative structural design manufactured in Z and X–Y directions under uniaxial compression loads according to the requirements of the Spanish CTE standard. The experimental results point to a mechanical linear behavior of PETG in X, Y and Z manufacturing directions up to strain levels close to the yield strength point. SEM micrographs show different structural failures linked to the specimen manufacturing directions. Test specimens manufactured along X present a brittle fracture caused by a delamination process. On the contrary, test specimens manufactured along X and Y directions show permanent plastic deformations, great flexibility and less strength under compression loads. Two numerical analyses were performed on the structural part using Young’s compression modulus obtained from the experimental tests and the load specifications required for the Spanish CTE standards. The comparison between numerical and experimental results presents a percentage of relative error of 2.80% (Z-axis), 3.98% (X-axis) and 3.46% (Y-axis), which allows characterizing PETG plastic material manufactured with FDM as an isotropic material in the numerical simulation software without modifying the material modeling equations in the data software. The research presented here is of great help to researchers working with polymers and FDM technology for companies that might need to numerically simulate new designs with the PETG polymer and FDM technology.

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A new conformal cooling lattice design procedure for injection molding applications based on expert algorithms

Cited by 49 publications

References 28 publications

Dynamic conformal cooling improves injection molding

Dynamic conformal cooling improves injection molding

A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models

Experimental and Numerical Analysis for the Mechanical Characterization of PETG Polymers Manufactured with FDM Technology under Pure Uniaxial Compression Stress States for Architectural Applications

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