Performance Evaluation of Cooling Systems in Injection Moulds Made of Steel and Aluminium Through Numerical Simulations

Soares, Ana Jacinta; Marconi, P.; Carvalho, Gimaézio Gomes; Júnior, Armando Sá Ribeiro; Beal, Valter Estevão; Ferreira, Cristiano Vasconcellos

doi:10.26678/abcm.cobef2023.cof23-0531

Procceedings of the 12th Brazilian Congress on Manufacturing Engineering 2023

DOI: 10.26678/abcm.cobef2023.cof23-0531

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Performance Evaluation of Cooling Systems in Injection Moulds Made of Steel and Aluminium Through Numerical Simulations

Ana Jacinta Soares¹,

P. Marconi²,

Gimaézio Gomes Carvalho³

et al.

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2024

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Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality

Marconi,

Amarante,

Ferreira

et al. 2024

Materials and Manufacturing

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<div>The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of thinner geometries, the results indicated that higher pressures were needed to completely fill the cavity. In addition, an increase in the warping of the parts was observed due to the solidification of the flow front, resulting in more pronounced pressure gradients along the part. Therefore, due to their lower stiffness and high thermal conductivity, aluminum molds would not be recommended for this type of geometry in high-production processes. For the cases associated with lower pressures (greater thicknesses), aluminum molds showed better dimensional quality compared to steel. This result indicates that these tools could be an interesting alternative for manufacturing large volumes of parts in aluminum molds.</div>

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Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality

Marconi,

Amarante,

Ferreira

et al. 2024

Materials and Manufacturing

View full text Add to dashboard Cite

show abstract

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Performance Evaluation of Cooling Systems in Injection Moulds Made of Steel and Aluminium Through Numerical Simulations

Cited by 1 publication

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Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality

Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality

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