Optimization of polygonal cross-sectioned conformal cooling channels in injection molding

Simiyu, Laura Wambani; Mutua, James M.; Muiruri, Patrick I.; Ikua, Bernard W.

doi:10.1007/s12008-023-01226-7

Cited by 5 publications

(8 citation statements)

References 54 publications

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“…Where, GC ij is the GRG, j is a distinct coefficient whose value spans from zero to one, Δ min and Δ max are the maximum and minimum absolute differences [43,71].…”

Section: Deviation Sequencementioning

confidence: 99%

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Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Kachomba,

Mutua,

Obiko

et al. 2024

Mater. Res. Express

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Wire-arc additive manufacturing (WAAM) has emerged as a critical tool for remanufacturing industrial components. A limited understanding of this technique for quality product manufacturing has hindered its utilisation for industrial applications. This study reports on the optimisation of WAAM process parameters for AISI 4130 steel towards remanufacturing of high-quality products for industrial applications. AISI 4130 steel was selected for this study due to its high strength-to-weight ratio, excellent weldability, and suitability for the WAAM process. Taguchi’s Grey Relational Analysis (GRA) used four factors and three levels in the multiple response optimisation process. The study considered process parameters voltage, current, travel speed and gas flow in the gas metal arc welding (GMAW)-based WAAM technique. Analysis of Variance (ANOVA) results show that voltage, travel speed and gas flow significantly affect material deposition. Voltage had the highest significance (31.61%) compared to other parameters. The optimised process parameters were found to be: voltage - 23V, current - 100A, travel speed - 350mm/min, and gas flow - 10L/min. These parameters resulted in tensile residual stresses of 25 ±74 MPa, microhardness of 171.4±12.2 HV0.3, and a relative density of 98.21%. The microstructural analysis reveals existence of predominant ferritic and pearlitic colonies. This is due to compounded thermal stresses during the deposition process and alloy composition resulting in tailored microstructure and mechanical properties. The study provides some insights into the WAAM remanufacturing process for producing highly quality industrial components.

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“…Where, GC ij is the GRG, j is a distinct coefficient whose value spans from zero to one, Δ min and Δ max are the maximum and minimum absolute differences [43,71].…”

Section: Deviation Sequencementioning

confidence: 99%

“…In this paper, PCA was used to estimate the best value of the coefficient, j in the GRC in equation (5), which is in the range 0 to 1 as a weighting factor [71][72][73].…”

Section: Principal Component Analysis (Pca)mentioning

confidence: 99%

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Kachomba,

Mutua,

Obiko

et al. 2024

Mater. Res. Express

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“…Computerized simulation has proven to be an indispensable tool for evaluating CCCs [ 3 , 4 , 5 , 6 , 7 , 8 ]. This tool enables mold designers to assess and demonstrate the advantages of adopting this injection mold design type over traditional molds with conventional cooling channels.…”

Section: Introductionmentioning

confidence: 99%

“…Within the field of injection mold simulation, there is an abundance of literature and research focused on the integration of conformal channels. This effort leverages a range of commercial software solutions, including but not limited to Moldex3D ® , Moldflow ® , and Solidworks ® Plastic [ 4 , 5 , 6 ]. These platforms are purpose-built to simulate the complete injection process holistically, including its myriad variables.…”

Section: Introductionmentioning

confidence: 99%

Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Vargas-Isaza,

Benitez-Lozano,

Rodriguez

2023

Polymers

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Injection molds are production tools that require detailed analysis based on the quality of the resulting part, the impact on cycle times, and the expected production volume. Cooling channels also play a critical role in mold performance and product quality as they largely determine cycle time. Designs that incorporate conformal cooling channel (CCC) geometries that conform to or align with the part contour are currently being explored as an alternative to conventional cooling channel designs in injection molds. In this study, a simulation of CCC geometries was performed and their effects on mold temperatures and warpage were investigated. Two cross-sectional geometries, circular and square, were selected for a three-factor level design of experiments (DOE) analysis. The response variables used were mold temperatures and part warpage. A cup-shaped part with upper and lower diameters of 54 and 48 mm, respectively, a height of 23 mm and a thickness of 3 mm was used for the injection molded part. A comparison was also made between two materials for the injection mold, steel and polycarbonate. The DOE results showed that the distance between the CCC and the injected part and the diameter or side of the square have significant effects on the response variables for both systems (steel and polycarbonate molds). In addition, a comparison between conventional and conformal cooling channels was analyzed using a cup-shaped part and a less rigid part geometry. The finite element simulation results show a 9.26% reduction in final warpage in the cup-shaped part using CCCs compared with the conventional cooling methods in steel. When using parts with lower geometry stiffness, the use of CCCs reduced final part warpage by 32.4% in metal molds and by 59.8% in polymer molds.

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“…Tan [7] designed a self-supporting cooling water path and found that the supporting rod increased the heat transfer area and the secondary flow was beneficial to improve the cooling efficiency. Simiyu et al [8] have analyzed the influence of cross-section shape on cooling efficiency and found that the decagonal section has a better cooling effect than the circular section. In this paper, the mold core is taken as the research object, the mold flow simulation is carried out by Moldflow software, and the temperature distribution of the mold core is improved by designing the lattice structure and noncircular cooling water path.…”

Section: Introductionmentioning

confidence: 99%

Design of Conformal Cooling System with Lattice-structure of Mold Based on 3D Printing

Zhao,

Chu,

Kang

et al. 2023

J. Phys.: Conf. Ser.

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The conformal cooling water circuit manufactured by using metal 3D printing SLM technology has significant advantages, compared to the straight drilling cooling water circuit, but there is still a problem of large temperature differences in local mold positions. Based on a circular cross-section spiral-shaped waterway, this article proposes a design that replaces a circular cross-section single helix with a runway-shaped double helix structure and sets a lattice structure in areas with large temperature differences. Finally, Moldflow is used to simulate the cooling effects of the two cooling forms. The results show that the lattice structure can significantly improve the phenomenon of uneven cooling, and the surface temperature difference of the mold has been improved by 41%. Compared to the circular section, the runway-shaped section has a better cooling effect, better temperature distribution, and more uniform cooling.

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Optimization of polygonal cross-sectioned conformal cooling channels in injection molding

Cited by 5 publications

References 54 publications

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Evaluating the Cooling Efficiency of Polymer Injection Molds by Computer Simulation Using Conformal Channels

Design of Conformal Cooling System with Lattice-structure of Mold Based on 3D Printing

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