Conformal Cooling Systems Design and Dimensioning for Injection Molds

Torres-Alba, Abelardo; Perete, Daniel Diaz; Martín-Doñate, Cristina; Mercado-Colmenero, Jorge Manuel

doi:10.1007/978-3-030-41200-5_18

Cited by 3 publications

(2 citation statements)

References 16 publications

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“…The spiral geometry is one of the most used topologies in the design of the layout in conformal cooling channels [ 11 ]. Linear zigzag geometry [ 12 , 13 ] is used in cases where spiral channels are difficult to implement. It should be noted that spiral geometry, in comparison to zigzag topology, presents sharp turns—increasing pressure drops, slowing the flow rate, and thus weakening the cooling efficiency.…”

Section: Introductionmentioning

confidence: 99%

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

et al. 2021

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The paper presents a hybrid cooling model based on the use of newly designed fluted conformal cooling channels in combination with inserts manufactured with Fastcool material. The hybrid cooling design was applied to an industrial part with complex geometry, high rates of thickness, and deep internal concavities. The geometry of the industrial part, besides the ejection system requirements of the mold, makes it impossible to cool it adequately using traditional or conformal standard methods. The addition of helical flutes in the circular conformal cooling channel surfaces generates a high number of vortexes and turbulences in the coolant flow, fostering the thermal exchange between the flow and the plastic part. The use of a Fastcool insert allows an optimal transfer of the heat flow in the slender core of the plastic part. An additional conformal cooling channel layout was required, not for the cooling of the plastic part, but for cooling the Fastcool insert, improving the thermal exchange between the Fastcool insert and the coolant flow. In this way, it is possible to maintain a constant heat exchange throughout the manufacturing cycle of the plastic part. A transient numerical analysis validated the improvements of the hybrid design presented, obtaining reductions in cycle time for the analyzed part by 27.442% in comparison with traditional cooling systems. The design of the 1 mm helical fluted conformal cooling channels and the use of the Fastcool insert cooled by a conformal cooling channel improves by 4334.9% the thermal exchange between the cooling elements and the plastic part. Additionally, it improves by 51.666% the uniformity and the gradient of the temperature map in comparison with the traditional cooling solution. The results obtained in this paper are in line with the sustainability criteria of green molds, centered on reducing the cycle time and improving the quality of the complex molded parts.

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Section: Introductionmentioning

confidence: 99%

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

et al. 2021

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“…Spiral geometry is one of the most used topologies in the design of the standard layout in conformal cooling channels [ 27 ]. Linear zigzag geometry [ 28 , 29 ] is used in cases where spiral circuits are difficult to implement. It should be noted that spiral geometry versus zigzag topology features sharp turns, increasing the pressure drop, slowing the flow rate, and thus weakening the cooling efficiency.…”

Section: Introductionmentioning

confidence: 99%

A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles

et al. 2021

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The paper presents a new design of conformal cooling channels, for application in collimator-type optical plastic parts. The conformal channels that are presented exceed the thermal and dynamic performance of traditional and standard conformal channels, since they implement new sections of complex topology, capable of meeting the high geometric and functional specifications of the optical part, as well as the technological requirements of the additive manufacturing of the mold cavities. In order to evaluate the improvement and efficiency of the thermal performance of the solution presented, a transient numerical analysis of the cooling phase has been carried out, comparing the traditional cooling with the new geometry that is proposed. The evolution of the temperature profile versus the thickness of the part in the collimating core with greater thickness and temperature, has been evaluated in a transient mode. The analysis of the thermal profiles, the calculation of the integral mean ejection temperature at each time of the transient analysis, and the use of the Fourier formula, show great improvement in the cycle time in comparison with the traditional cooling. The application of the new conformal design reduces the manufacturing cycle time of the collimator part by 10 s, with this value being 13% of the total manufacturing cycle of the plastic part. As a further improvement, the use of the new cooling system reduces the amount of thickness in the collimator core, which is above the ejection temperature of the plastic material. The improvement in the thermal performance of the design of the parametric cooling channels that are presented not only has a significant reduction in the cycle time, but also improves the uniformity in the temperature map of the collimating part surface, the displacement field, and the stresses that are associated with the temperature gradient on the surface of the optical part.

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Design and Manufacturing of Conformal Cooling Channels for Injection Molding: A Review

Gotlih

Karner

Belšak

et al. 2023

Lecture Notes in Networks and Systems

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Conformal Cooling Systems Design and Dimensioning for Injection Molds

Cited by 3 publications

References 16 publications

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles

Design and Manufacturing of Conformal Cooling Channels for Injection Molding: A Review

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