Study on an Optimized Configuration of Conformal Cooling Channel by Branching Law

Choi, Jae-Hun; Kim, Jin Su; Han, Eun Su; Park, Hyung Pil; Rhee, Byong-Duk

doi:10.1115/esda2014-20431

Cited by 17 publications

(10 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Unfortunately, the design of a lattice topology conformal cooling system requires a detailed study regarding flow distribution and pressure drops since the usual design rules are useful for channel geometries with uniform diameters and shapes. In line with the admissible pressure drop in the layout, there is a minimum channel diameter below which the channel cannot be divided into sub-branches [ 16 ]. In addition, from a functional point of view, in the event of obstruction in the channels due to foreign bodies, it would be difficult to remove it due to the communication of the channels with each other.…”

Section: Introductionmentioning

confidence: 99%

“…Table 9 and Figures [16][17][18] show the magnitude of the heat flow that is exchanged between the computational domain of the cooling channels and the rest of the domains defined for each of the numerical simulations performed. As can be seen in Table 9 and Figures 16-18, the design of some conformal-type cooling channels together with the implementation of a Fastcool insert, used for cooling the plastic part, represents a relevant improvement in the heat exchange that takes place between the coolant flow and the plastic part.…”

mentioning

confidence: 99%

See 1 more Smart Citation

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

et al. 2021

View full text Add to dashboard Cite

The paper presents a hybrid cooling model based on the use of newly designed fluted conformal cooling channels in combination with inserts manufactured with Fastcool material. The hybrid cooling design was applied to an industrial part with complex geometry, high rates of thickness, and deep internal concavities. The geometry of the industrial part, besides the ejection system requirements of the mold, makes it impossible to cool it adequately using traditional or conformal standard methods. The addition of helical flutes in the circular conformal cooling channel surfaces generates a high number of vortexes and turbulences in the coolant flow, fostering the thermal exchange between the flow and the plastic part. The use of a Fastcool insert allows an optimal transfer of the heat flow in the slender core of the plastic part. An additional conformal cooling channel layout was required, not for the cooling of the plastic part, but for cooling the Fastcool insert, improving the thermal exchange between the Fastcool insert and the coolant flow. In this way, it is possible to maintain a constant heat exchange throughout the manufacturing cycle of the plastic part. A transient numerical analysis validated the improvements of the hybrid design presented, obtaining reductions in cycle time for the analyzed part by 27.442% in comparison with traditional cooling systems. The design of the 1 mm helical fluted conformal cooling channels and the use of the Fastcool insert cooled by a conformal cooling channel improves by 4334.9% the thermal exchange between the cooling elements and the plastic part. Additionally, it improves by 51.666% the uniformity and the gradient of the temperature map in comparison with the traditional cooling solution. The results obtained in this paper are in line with the sustainability criteria of green molds, centered on reducing the cycle time and improving the quality of the complex molded parts.

show abstract

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Unfortunately, the design of a lattice conformal cooling system requires detailed study regarding flow distribution and pressure drop, since the usual design rules are useful for channel geometries with uniform diameters and shapes. In line with the admissible pressure drop in the circuit, there is a minimum channel diameter below which the channel cannot be divided into sub-branches [ 34 ]. Also, from a functional point of view, in the event of an obstruction situation in the channels, by foreign bodies, it would be difficult to extract them due to the communication of the channels between them.…”

Section: Introductionmentioning

confidence: 99%

A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles

et al. 2021

View full text Add to dashboard Cite

The paper presents a new design of conformal cooling channels, for application in collimator-type optical plastic parts. The conformal channels that are presented exceed the thermal and dynamic performance of traditional and standard conformal channels, since they implement new sections of complex topology, capable of meeting the high geometric and functional specifications of the optical part, as well as the technological requirements of the additive manufacturing of the mold cavities. In order to evaluate the improvement and efficiency of the thermal performance of the solution presented, a transient numerical analysis of the cooling phase has been carried out, comparing the traditional cooling with the new geometry that is proposed. The evolution of the temperature profile versus the thickness of the part in the collimating core with greater thickness and temperature, has been evaluated in a transient mode. The analysis of the thermal profiles, the calculation of the integral mean ejection temperature at each time of the transient analysis, and the use of the Fourier formula, show great improvement in the cycle time in comparison with the traditional cooling. The application of the new conformal design reduces the manufacturing cycle time of the collimator part by 10 s, with this value being 13% of the total manufacturing cycle of the plastic part. As a further improvement, the use of the new cooling system reduces the amount of thickness in the collimator core, which is above the ejection temperature of the plastic material. The improvement in the thermal performance of the design of the parametric cooling channels that are presented not only has a significant reduction in the cycle time, but also improves the uniformity in the temperature map of the collimating part surface, the displacement field, and the stresses that are associated with the temperature gradient on the surface of the optical part.

show abstract

“…Wang et al presented an automatic method for designing conformal cooling circuits by establishing a relationship between the conformal cooling and the shape of the plastic body [28]. Choi et al established a higher degree of freedom in the design of conformal cooling channels with the application of additive manufacturing and concentrate on a branching law principle to improve the cooling efficiency in injection molds [29]. To create the design of conformal cooling channels, they used the Voronoi diagram algorithm and the binary branching algorithm.…”

Section: Introductionmentioning

confidence: 99%

A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Jahan

El-Mounayri

2018

Applied Sciences

View full text Add to dashboard Cite

Plastic injection molding is a versatile process, and a major part of the present plastic manufacturing industry. The traditional die design is limited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermomechanical) performance. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum conformal channels based on thermomechanical performance are not found in the literature. This paper proposes a design methodology to generate optimized design configurations of such channels in plastic injection molds. The design of experiments (DOEs) technique is used to study the effect of the critical design parameters of conformal channels, as well as their cross-section geometries. In addition, designs for the “best” thermomechanical performance are identified. Finally, guidelines for selecting optimum design solutions given the plastic part thickness are provided.

show abstract

Study on an Optimized Configuration of Conformal Cooling Channel by Branching Law

Cited by 17 publications

References 0 publications

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

A Hybrid Cooling Model Based on the Use of Newly Designed Fluted Conformal Cooling Channels and Fastcool Inserts for Green Molds

A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles

A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

Contact Info

Product

Resources

About