Design and optimization of conformal cooling channels for injection molding: a review

Kanbur, Barış Burak; Shen, Shunyao; Duan, Fei

doi:10.1007/s00170-019-04697-9

Cited by 78 publications

(50 citation statements)

References 68 publications

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“…Considering this and that the tooling costs (Ci 3 ) are equal to zero, the equilibrium point between the cost levels per produced part in scenarios (0) and (3) can be obtained as presented in Equations ( 8) and (9).…”

Section: Economic Analysis Of the Production Of Swimming Pool Sink Cage Ribs Via Multi Jet Fusion Technologymentioning

confidence: 99%

“…This technology implementation consists of implementing channels that physically follow the contours of the part to be injected. Conformal cooling strategies are used to avoid the previous cooling approaches whereby cooling channels had to be machined and/or deep drilled, thus avoiding complexity and the potentially uneven interconnection of the cooling pipes [9]. Furthermore, the use of such channels has proven to improve injection effects, such as warping and sink marks [10], and has been assessed in applications of micro injection moulding [11].…”

Section: Introductionmentioning

confidence: 99%

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SLM Manufacturing Redesign of Cooling Inserts for High Production Steel Moulds and Benchmarking with Other Industrial Additive Manufacturing Strategies

Minguella-Canela

Planas²,

Santos-López

2020

Materials

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Moulding technologies are remarkably effective for parts requiring high production volumes. Yet cooling the moulds after each injection can cause a significant loss of time. A possibility for reducing the cooling times is to use cooling inserts and conformal cooling strategies. In the present case, the original inserts of a mould must be substituted because the original material cannot be utilized anymore (toxicity). Will it be technically feasible to achieve a proper cooling only by modifying the inserts? Here, the cooling inserts of high production steel moulds utilized to manufacture ribs for swimming pool sinks’ plastic cages are redesigned, simulated and manufactured, taking advantage of Selective Laser Melting possibilities and without modifying the geometry of the obtained parts, nor the rest of the moulds. The results reveal a reduction in the mould cooling times of up to 8%, while maintaining the same conformation properties, thus leading to important savings of time and some global costs in the production outcomes. The study also benchmarks the production economic limits of this approach compared to other possible strategies, such as the development of full new conformal cooling moulds or the industrial production of the parts with plastic additive manufacturing (multi jet fusion) technology.

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Section: Economic Analysis Of the Production Of Swimming Pool Sink Cage Ribs Via Multi Jet Fusion Technologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

SLM Manufacturing Redesign of Cooling Inserts for High Production Steel Moulds and Benchmarking with Other Industrial Additive Manufacturing Strategies

Minguella-Canela

Planas²,

Santos-López

2020

Materials

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show abstract

“…Kanbur al. [ 28 ] reviewed the design and optimization of CCC for injection molding. This study also discussed the 3D models of CCC and relevant mold materials.…”

Section: Introductionmentioning

confidence: 99%

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Kuo

2021

Polymers

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Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

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“…In the industry, the productivity is a key issue for large-volume production since it is closely related to the cooling time of the injection molded parts. To decrease the cooling time, the conformal cooling channel (CCC) [1] was employed in the molds or dies. Some additive manufacturing (AM) technologies [2,3], including fused deposition modeling, direct metal laser sintering (DMLS), vacuum diffusion bonding, selective laser sintering, selective laser melting or selective electron beam melting were widely employed to manufacture physical models, microchannels [4], molds or dies.…”

Section: Introductionmentioning

confidence: 99%

A low-cost and highly efficient method of reducing coolant leakage for direct metal printed injection mold with cooling channels using optimum heat treatment process procedures

Kuo

Qiu

Yang

2021

Int J Adv Manuf Technol

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Metal additive manufacturing (MAM) provides lots of bene ts and potentials in manufacturing molds or dies with sophisticated conformal cooling channels. It is known that the conformal cooling technology provides effective cooling to reduce cycle time for increasing productivity. Ordinarily, mold inserts fabricated by general printing procedures will result in coolant leakage in the injection molding process.The yield in the manufacturing of fully dense injection molding tools was limited to the very narrow working widow. In addition, high costs of fully dense injection mold fabricated by MAM constitute the major obstacle to its application in the mold or die industry. In general, the high cost of MAM is approximately 50-70% more expensive than conventional computer numerical control machining. In this study, a low-cost and highly e cient method of reducing coolant leakage for direct metal printed injection mold with cooling channels was proposed. This new method employs general process parameters to manufacture the green injection mold rapidly and then uses optimum heat treatment (HT) procedures to improve microstructure of the green injection mold. The results of this study revealed that optimum HT procedures can prevent coolant leakage and save manufacturing time of the injection mold fabricated by direct metal laser sintering. The evolution mechanisms of microstructure were investigated experimentally. The save in the injection mold manufacture time about 67% can be obtained.

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Design and optimization of conformal cooling channels for injection molding: a review

Cited by 78 publications

References 68 publications

SLM Manufacturing Redesign of Cooling Inserts for High Production Steel Moulds and Benchmarking with Other Industrial Additive Manufacturing Strategies

SLM Manufacturing Redesign of Cooling Inserts for High Production Steel Moulds and Benchmarking with Other Industrial Additive Manufacturing Strategies

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

A low-cost and highly efficient method of reducing coolant leakage for direct metal printed injection mold with cooling channels using optimum heat treatment process procedures

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