Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Çalışkan, Cemal İrfan; Koca, Aliihsan; Özer, Gökhan; Akbal, Ömer; Bakır, Soner

doi:10.1007/s00170-023-11389-y

Cited by 5 publications

(3 citation statements)

References 39 publications

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“…The presence of Cu, Ni, Fe metal phases and their alloy combinations further enhances electrical conductivity, toughness, and strength 9 . Normally, cermets like cutting tools of WC–Co 10 and Ti(C,N)/TiC–Ni, 11 inert anodes of NiFe 2 O 4 –Cu–Ni, 12 temperature sensors of Mo–W–ZrO 2 , 13 and solid oxide fuel cells of Ni–ZrO 2 –Y 2 O 3 14 are fabricated by conventional powder metallurgy techniques, 15,16 infiltration method, 17 spark plasma sintering, 18 and hot pressing 19 . Based on this, cermet usually showed a simple shape limited by the processing molds.…”

Section: Introductionmentioning

confidence: 99%

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

Fu,

Zou,

Kang

et al. 2024

Int J Applied Ceramic Tech

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Carbon‐free aluminum electrolysis is crucial for achieving the low‐carbon development and carbon neutrality in the future aluminum industry. NiFe2O4‐based cermet is the potential candidate of inert anode, benefiting from the satisfactory corrosion resistance and high‐temperature conductivity. Herein, complex‐shaped 25(Cu–20Ni)/(NiFe2O4–10NiO) cermets were fabricated via a plastic shaping method using the polyformaldehyde (POM)‐based granular feedstock. The feedstock showed uniform microstructure with evenly dispersed powders wrapped in polymers, which exhibited shear‐thinning behavior during molding. Roles of the feedstock with different powder loadings in the morphology and bending strength of the cermets were investigated. High‐precision gear parts exhibited no deformation, a high relative density over 98%. Investigation of different powder loadings revealed that parts prepared with a 56 vol% loading demonstrate the excellent performance, and possessed an impressive flexural strength of 178.4 MPa. This achievement provided a foundation for the future utilization of complex‐shaped inert anode material components in industrial applications.

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Section: Introductionmentioning

confidence: 99%

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

Fu,

Zou,

Kang

et al. 2024

Int J Applied Ceramic Tech

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“…Additive manufacturing (AM) increases the design freedom of parts (Bikas et al, 2019;Xiong et al, 2022), especially for parts with flow channels (Zhang et al, 2020). As mentioned in a literature (Biedermann et al, 2022), these parts include hydraulic manifolds (Diegel et al, 2020;Alshare et al, 2019;Rolinck et al, 2021;Arena et al, 2023;Schmelzle et al, 2015), nozzles (Biedermann and Meboldt, 2020;Gradl and Protz, 2020), injection moulds with conformal channels (Çalis kan et al, 2023;Gao et al, 2021) and heat exchangers (Dixit et al, 2022;Liang et al, 2023). Compared to conventional manufacturing methods for flow channels, hydraulic flow channels based on AM design have many advantages (Biedermann et al, 2022).…”

Section: Introductionmentioning

confidence: 99%

“…, 2023; Schmelzle et al. , 2015), nozzles (Biedermann and Meboldt, 2020; Gradl and Protz, 2020), injection moulds with conformal channels (Çalişkan et al. , 2023; Gao et al.…”

Section: Introductionmentioning

confidence: 99%

A novel design model of flow channel paths for additive manufacturing

Li,

Wang,

Dai

2024

RPJ

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Purpose This paper aims to propose a method for automatic design of additive manufacturing (AM) flow channel paths driven by path length and pressure loss. The research focuses on the automatic design of channel paths, intending to achieve the shortest flow channel length or minimum pressure loss and improve the design efficiency of AM parts. Design/methodology/approach The initial layout of the flow channels is redesigned to consider the channels print supports. Boundary conditions and constraints are defined according to the redesigned channels layout, and the equation consisting of channel length and pressure loss is used as the objective function. Then the path planning simulation is performed based on particle swarm algorithm. The proposed method describes the path of flow channels using spline cures. The spline curve is controlled by particle (one particle represents a path), and the particle is randomly generated within the design space. After the path planning simulation is completed, the generated paths are used to create 3D parts. Findings Case study 1 demonstrates the automatic design of hydraulic spool valve. Compared to conventional spool valve, the pressure loss was reduced by 86% and the mass was reduced by 83%. The design results of case study 2 indicate that this approach is able to find the shortest channel path with lower computational cost. Originality/value The automatic design method of flow channel paths driven by path length and pressure loss presented in this paper provides a novel solution for the creation of AM flow components.

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Additively manufactured conformal cooling channels through topology optimization

Lamarche-Gagnon,

Molavi-Zarandi,

Raymond

et al. 2024

Struct Multidisc Optim

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Cooling channels play a critical role in various casting and molding processes, impacting both the cycle time and quality of the product. As additive manufacturing technologies become increasingly prevalent, conventional straight-drilled channels are being progressively substituted by intricate cooling lines that conform to the contours of the fabricated part. This transition can lead to a significant reduction of the solidification time and temperature gradients, consequently lowering the occurrence of part defects. However, designing such channels becomes challenging as geometric complexity and manufacturing constraints increase. In this work, we present a density-based topology optimization approach to generate conformal cooling channels in molds and dies inserts. To mitigate temperature variations, the objective function is penalized using the temperature standard deviation of the insert cavity surface. A density-gradient-based constraint is further utilized to reduce the generation of overhanging structures and promote manufacturability. In particular, the use of this constraint leads to the generation of channels characterized by a teardrop-shaped cross section. The cooling efficiency of a selected optimized design is confirmed through computations using a body-fitted solver. The geometry is subsequently manufactured by Laser Powder Bed Fusion (LPBF) and experiments are conducted to compare its performance in comparison to a design featuring straight-drilled channels. The results demonstrate that the optimized geometry significantly enhances the heat extraction rate and further leads to a 43% reduction of the cavity temperature standard deviation.

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Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Cited by 5 publications

References 39 publications

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

A novel design model of flow channel paths for additive manufacturing

Additively manufactured conformal cooling channels through topology optimization

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Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Cited by 5 publications

References 39 publications

Plastic shaping of NiFe2O4‐based cermets using granular feedstock: microstructure and mechanical properties

Plastic shaping of NiFe2O4‐based cermets using granular feedstock: microstructure and mechanical properties

A novel design model of flow channel paths for additive manufacturing

Additively manufactured conformal cooling channels through topology optimization

Contact Info

Product

Resources

About

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties

Plastic shaping of NiFe₂O₄‐based cermets using granular feedstock: microstructure and mechanical properties