Development and application of a conformal cooling channel with easy removal and smooth surfaces

Kuo, Chil-Chyuan; You, Zheng-Yan; Wu, Junyi; Huang, Junlin

doi:10.1007/s00170-019-03316-x

Cited by 17 publications

(5 citation statements)

References 24 publications

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“…In general, the surface quality of the mold fabricated by direct metal laser sintering, vacuum diffusion bonding, or electron beam melting was not good due to staircase effect [27]. A distinct advantage was found that no extensive machining was needed to obtain the required surface roughness and tolerance compared to an injection mold fabricated by direct metal laser sintering, vacuum diffusion bonding, or electron beam melting, since injection mold was fabricated by casting process [28][29][30][31]. Figure 15 shows the photos of the conventional cooling channels and optimum CCCs.…”

Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

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Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…Also, conformal cooling channels can be used to manipulate the local temperature field. Mostly these channels are used to improve the cooling efficiency and thus the cycle time, since the cooling channels are much closer to the cavity surface than with conventional cooling channels [6][7][8]. Since most conformal cooling channels are complex-shaped, they need to be manufactured using additive manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of a self‐optimizing local mold temperature control for inline warpage reduction of injection molded parts

Hopmann,

Kahve,

Fritsche

et al. 2024

Materialwissenschaft Werkst

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Dimensional accuracy is a highly important quality criterion for injection molded parts and due to the decreasing tolerance criteria an ongoing issue for mold makers, part designers and manufacturers. Variations in the molding process regarding temperature, pressure and thus the specific volume are leading to inner stress distributions within the part, which ultimately cause warpage. To reduce warpage, a homogenization of the local melt properties, such as the temperature, cooling rate or specific volume is necessary. To be able to manipulate these melt properties locally, a mold with a highly segmented temperature control, consisting of 18 heating ceramics and carbon dioxide expansion chambers was designed. This work seeks to reduce warpage using a newly developed control loop that adjusts target values for the upcoming molding cycle while considering the control error of the previous cycle. The self‐optimizing control loop‐ aiming to homogenize the local mold temperatures over multiple cycles‐ was evaluated in experimental trials. Test specimens were produced, and measured for warpage. Compared to the reference (no control), the warpage of a plate‐shaped geometry was reduced by 10 % with the mold temperature homogenization approach.

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“…Rapid tooling, a term denoting the expedited production of molds or tooling components while bypassing intricate and time-consuming mechanical procedures, can be classified into either 'soft' or 'hard' categories, contingent upon the base material utilized, such as high-strength steel [5,6] or softer materials like polymers [1,2,7], silicone rubbers [8], or epoxy resins [7,9,10]. This classification also extends to the differentiation between 'direct' and 'indirect' production methods [7,11], depending on whether the mold is fabricated directly via AM, for instance, or indirectly through casting on a master pattern.…”

Section: Introductionmentioning

confidence: 99%

“…Soft tooling that incorporates conformal cooling channels (CCs) can employ a hybrid manufacturing technique as well, involving the initial 3D printing of CCs using AM technology, followed by their subsequent deployment in an indirect process to cast a mold, with silicone rubber [8] or epoxy resin [12] as potential casting materials. While indirect tooling usually requires more manufacturing steps and specific procedures for CCs' material removal [10], AM can overcome this by manufacturing a mold in one single step, which can eventually offer superior accuracy and thermomecanical properties [8,11]. Leveraging recent advancements in AM technology, particularly the utilization of charged high-performance thermoplastic polymers [13,14], the study and enhancement of the thermal performance of a soft polymeric mold directly manufactured by AM are the main concerns of this work.…”

Section: Introductionmentioning

confidence: 99%

A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

Storti,

Sobotka

2024

Applied Thermal Engineering

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Development and application of a conformal cooling channel with easy removal and smooth surfaces

Cited by 17 publications

References 24 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Evaluation of a self‐optimizing local mold temperature control for inline warpage reduction of injection molded parts

A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

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