Design and additive manufacturing of novel conformal cooling molds

Tan, Chaolin; Wang, Di; Ma, Wanbiao; Chen, Yaorong; Chen, Shijin; Yang, Yongqiang; Zhou, Kesong

doi:10.1016/j.matdes.2020.109147

Cited by 77 publications

(28 citation statements)

References 29 publications

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“…It is crucial to make sure that the value of L 1 does not exceed 10 mm in any case. In this way, material collapses are avoided in the fabrication of the conformal channel [ 19 ]. The second part of the curve S j is formed by the set of points P j belonging to the geometric locus L 2 , see Figure 6 .…”

Section: Methodsmentioning

confidence: 99%

“…The use of these technologies requires the fulfillment of a series of dimensional criteria that are necessary to guarantee the structural integrity of the mold against the high pressures and efforts to which it will be subjected during its productive life. Additionally, subtractive technologies present high levels of material waste, so unfortunately they are not in line with the current sustainability requirements [ 17 , 18 , 19 ]. On the contrary, the additive manufacturing process allows greater freedom in the manufacturing and design of conformal channels, adapting the channel topology to the requirements of the geometric surface of the plastic part [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Methodsmentioning

confidence: 99%

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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“…Recently, fully dense Al‐, [ 30–35 ] Ti‐, [ 36–39 ] Fe‐, [ 40–45 ] TiAl‐, [ 46,47 ] and Inconel‐ [ 48,49 ] based metal matrix composites have been successfully fabricated by PBF‐L. Few other AM processes that can fabricate metal matrix composites (MMCs) are DED‐L [ 50,51 ] and cold spray AM.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, fully dense Al-, [30][31][32][33][34][35] Ti-, [36][37][38][39] Fe-, [40][41][42][43][44][45] TiAl-, [46,47] and Inconel- [48,49] based metal matrix composites have been successfully fabricated by PBF-L. Few other AM processes that can fabricate metal matrix composites (MMCs) are DED-L [50,51] and cold spray AM. [52] In this review, the state-of-art materials, methods, and challenges associated with the fabrication of AMMCs by the AM processing (mostly PBF-L) will be addressed.…”

mentioning

confidence: 99%

Additive Manufacturing of Aluminum‐Based Metal Matrix Composites—A Review

et al. 2021

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Aluminum metal matrix composites (AMMCs) offer the potential to combine the advantages of both the aluminum alloys (low density and high ductility) and the reinforcements (high strength and high elastic modulus [EM]), therefore show superior specific strength, high specific stiffness, low coefficient of thermal expansion (CTE), and outstanding wear resistance. [1,2] Therefore, AMMCs meet the rapidly growing demand of advanced lightweight materials in many industrial areas such as automotive, aerospace, marine, and military. Traditionally, AMMCs are produced by two processing routes: melt processing or powder metallurgy. Although such composites are already in use in the aerospace and automobile sectors, many challenges in both melt and powder metallurgy processing routes prevent their widespread applications. The main challenges associated with the melt processing route are heterogeneous distribution of reinforcement leading to aggregation (due to the poor wettability of reinforcement), detrimental reactions at the interface (due to the high temperature of melt and a long dwell time of reinforcement in the melt), and difficulty in subsequent machining (due to the presence of hard second-phase particles). On the contrary, powder metallurgy processed AMMCs are prone to high levels of porosity and inferior mechanical properties leading to premature failure of the components. [3][4][5][6][7] In this context, additive manufacturing (AM) methods such as laser-based powder bed fusion (PBF-L), electron beam-based

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“…However, their thermal results were only evaluated by thermal simulation instead of experimental tests. Tan et al 13 designed and manufactured a new injection mold with conformal cooling channels by laser powder bed fusion. The diameters of the cooling channels manufactured by supportless and self-supporting methods can reach 10 mm and 20 mm, respectively.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

Han

Zhang

Ruan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Additive manufacturing has been proven to be a promising technology for fabricating high-performance dies, molds, and conformal cooling channels. As one of the manufacturing methods, wire and arc additive manufacturing displays unique advantages of low cost and high deposition rate that are better than other high energy beam-based ones. This paper presents a preliminary study of fabricating integrated cooling channels by CMT-based wire and arc additive manufacturing process. The deposition strategies for fabricating circular cross-sectional cooling channels both in conformal and straight-line patterns have been investigated. It included optimizing the welding torch angle, fabricating the enclosed semicircle structure and predicting the collision between the torch and constructed part. The cooling effect test was also conducted on both the conformal cooling channel and straight-line cooling channel. The results affirmed a higher cooling efficiency and better uniform cooling effect of the conformal cooling channel than straight-line cooling channel.

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Design and additive manufacturing of novel conformal cooling molds

Cited by 77 publications

References 29 publications

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

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

Additive Manufacturing of Aluminum‐Based Metal Matrix Composites—A Review

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

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