Experimental comparison of the flow rate and cooling performance of internal cooling channels fabricated via selective laser melting and conventional drilling process

Liu, Changyong; Cai, Zhixiang; Dai, Yuhong; Huang, Ninggui; Xing, Feng; Lao, Changshi

doi:10.1007/s00170-018-1799-y

Cited by 43 publications

(12 citation statements)

References 36 publications

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“…This result shows that an injection mold with sophisticated CCCs can be fabricated easily by RTT. Note that it is very difficult to fabricate these injection molds with intricate geometries using conventional machining [ 26 ]. 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 ].…”

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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“…Recent researches successful displayed the complete feasibility of SLM high laser reflective copper alloy [12], refractory pure tungsten [13], functional multi-materials [14], and graded lattice structures [15]. Consequently, the SLM technology is an efficient method to expand application circumstances and fields of MS, such as conformal cooling injection tooling [16,17], MS-based functional multi-materials [14,18], and geometrically complex aircraft components which need excellent mechanical properties but small quantities.…”

Section: Introductionmentioning

confidence: 99%

Microstructural characterization and properties of selective laser melted maraging steel with different build directions

Tan

Zhou

Min

et al. 2018

Science and Technology of Advanced Materials

201

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A nearly fully dense grade 300 maraging steel was fabricated by selective laser melting (SLM) additive manufacturing with optimum laser parameters. Different heat treatments were elaborately applied based on the detected phase transformation temperatures. Microstructures, precipitation characteristics, residual stress and properties of the as-fabricated and heat-treated SLM parts were systematically characterized and analyzed. The observed submicron grain size (0.31 μm on average) suggests an extremely high cooling rate up to 10 7 K/s. Massive needle-shaped nanoprecipitates Ni 3 X (X = Ti, Al, Mo) are clearly present in the martensitic matrix, which accounts for the age hardening. The interfacial relations between the precipitate and matrix are revealed by electron microscopy and illustrated in detail. Strengthening mechanism is explained by Orowan bowing mechanism and coherency strain hardening. Building orientation-based mechanical anisotropy, caused by 'layer-wise effect', is also investigated in as-fabricated and heat-treated specimens. The findings reveal that heat treatments not only induce strengthening, but also significantly relieve the residual stress and slightly eliminate the mechanical anisotropy. In addition, comprehensive performance in terms of Charpy impact test, tribological performance, as well as corrosion resistance of the as-fabricated and heat-treated parts are characterized and systematically investigated in comparison with traditionally produced maraging steels as guidance for industry applications.

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“…Figure 18 provides an overview of the cooling channels together with a sectional view of the tool from two different perspectives. According to the literature, the channel diameters ( Table 6 ) obtained by PBF without support structures yielded reasonable surface roughness for AlSi10Mg [ 27 ] that was used for the prototype and the tool steel [ 28 ].…”

Section: Resultsmentioning

confidence: 99%

Towards Enhancing the Potential of Injection Molding Tools through Optimized Close-Contour Cooling and Additive Manufacturing

Gries

Meyer

Wonisch³

et al. 2021

Materials

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This work deals with the parametric optimization of the position and form of a conformal cooling used in the injection molding industry. Based on a literature survey, an optimization routine concerning the parameter optimization of cooling system designs was developed and implemented with the help of the software package Moldflow. The main objective of the optimization is to reduce the cooling time; the second is to obtain an optimized homogeneous temperature distribution over the complete tool surface. To enable a comparison of the new close-contour solution with a classical manufacturing process, an optimized cooling system simulation, based on a conventional manufacturing solution, was established. It can be shown that the optimized close-contour cooling design offers significant advantages that cannot be exploited using classical manufacturing. Finally, the additive manufacturing of a prototype in the framework of powder bed fusion is documented as a proof of concept.

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Experimental comparison of the flow rate and cooling performance of internal cooling channels fabricated via selective laser melting and conventional drilling process

Cited by 43 publications

References 36 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

Microstructural characterization and properties of selective laser melted maraging steel with different build directions

Towards Enhancing the Potential of Injection Molding Tools through Optimized Close-Contour Cooling and Additive Manufacturing

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