Warpage Optimisation on the Moulded Part with Straight Drilled and Conformal Cooling Channels Using Response Surface Methodology (RSM), Glowworm Swarm Optimisation (GSO) and Genetic Algorithm (GA) Optimisation Approaches

Hanid, Mohd Hazwan Mohd; Rahim, Shayfull Zamree Abd; Gondro, J.; Sharif, Safian; Abdullah, Mohd Mustafa Al Bakri; Zain, Azlan Mohd; El-Hadj, A. Abdellah; Saad, Mohd Nasir Mat; Wysłocki, J.J.; Nabiałek, M.

doi:10.3390/ma14061326

Cited by 17 publications

(4 citation statements)

References 41 publications

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“…It was found that the thermal stability of addition-cured liquid silicone rubber was improved significantly. A conformal cooling channel (CCC) was employed in the plastic injection molding to enhance productivity and molded part quality [ 3 , 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Kuo

Tasi

Hunag³

2022

Polymers

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Liquid silicone rubber (LSR) parts have some distinct characteristics such as superior heat stability, low-temperature flexibility, aging resistance, and chemical resistance. From an industrial standpoint, the uniform vulcanization temperature of LSR is an important research point. However, the uniformity of the vulcanization temperature of LSR has been limited since the layout of the cartridge heater incorporated in the conventional steel mold does not follow the profile of the mold cavity. Metal additive manufacturing can be used to make LSR injection molds with conformal heating channels and conformal cooling channels simultaneously. However, this method is not suitable for a mold required to develop a new LSR product. In this study, a cost-effective approach was proposed to manufacture an LSR injection mold for the pilot run of a new optical lens. A rapid tool with low vulcanization energy consumption channels was proposed, which was incorporated with both a conformal heating channel (CHC) and conformal cooling channel (CCC) simultaneously. The function of the CHC was to vulcanize the LSR in the cavity uniformly, resulting in a shorter cycle time. The function of the CCC was to keep the LSR in a liquid state for reducing runner waste. It was found that the equation of y = −0.006x3 + 1.2114x2 − 83.221x + 1998.2 with the correlation coefficient of 0.9883 seemed to be an optimum trend equation for predicting the solidification time of a convex lens (y) using the vulcanizing hot water temperature (x). Additionally, the equation of y = −0.002x3 + 0.1329x2 − 1.0857x + 25.4 with the correlation coefficient of 0.9997 seemed to be an optimum prediction equation for the solidification time of a convex lens (y) using the LSR weight (x) since it had the highest correlation coefficient. The solidification time of a convex lens could be reduced by about 28% when a vulcanizing hot water temperature of 70 °C was used in the LSR injection mold with CHC.

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Section: Introductionmentioning

confidence: 99%

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Kuo

Tasi

Hunag³

2022

Polymers

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“…They used Taguchi Design of Experiment (DOE) method and recommended an optimal setting for optimization of both shrinkage and cycle time together. Hanid et al [20] applied Moldflow and optimisation methods to report that CCCs can improve the component quality by reduction of the warpage.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Conventional and Conformal Cooling Channels in the Production of a Commercial Injection-Moulded Component

Kariminejad

Kadivar

McAfee

et al. 2022

KEM

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Cooling channels are critical in injection mould tooling as cooling performance influences component quality, cycle time, and overall process efficiency. Additively Manufactured moulds allow the incorporation of cooling channels conforming to the shape of the cavity and core to improve heat removal. These conformal channels can reduce the cycle time, reduce mould temperature, and enhance the temperature uniformity on the mould's surface, leading to improved quality of the moulded components and reduced wastage in the production. The design of such channels is more challenging than conventional channels; thus, Computer-Aided Engineering (CAE) has a significant role within the design process. In this paper, a novel design for conformal cooling channels for the production of a commercial component from an industrial partner is investigated. This component had issues of high cycle time and a high defect rate due to residual stresses, resulting in component shrinkage. First, the existing conventional drilled cooling channels in the mould were simulated in Autodesk Moldflow Insight to evaluate temperature distribution and cycle time. Based on the temperature distribution, conformal cooling channels were designed in Solidworks, addressing the problem areas. Next, a simulation of fluid flow in the conformal channels was conducted in ANSYS-Fluent to ensure equal flow distribution in the entire circuit, iteratively arriving at an optimal configuration. Finally, the results of the new conformal channels, including mould temperature and cycle time, were compared with conventional cooling channels in simulation. The results showed a significant reduction in cycle time and improvement in the temperature distribution, thereby minimising residual stresses and shrinkage.

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“…The popularity of polymers is associated with relatively low prices, a very good price-quality ratio and general availability [ 3 ]. Requirements for their operating, strength and aesthetic properties are growing very dynamically [ 4 , 5 ], motivating more and more scientists and companies to search for new manufacturing technologies or their improvements [ 6 , 7 , 8 ]. Nowadays, despite many years of usage, still the most developing technology is injection molding [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Application of Selective Induction Heating for Improvement of Mechanical Properties of Elastic Hinges

et al. 2021

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Injection molding is a polymer processing technology used for manufacturing parts with elastic hinges. Elastic hinges are widely used in FMCG (Fast Moving Consumer Goods) packaging (e.g., bottle closures of shampoos, sauces) and in the electrical engineering industry. Elastic hinge is a thin film that connect two regions of the injection molded part, where significant shear rates are present, which can lead to the degradation of polymers and the decrease in mechanical properties. Selective induction heating is the method that improves the flow of the polymer melt through thin regions by the local increase in mold temperature. In this study, selective induction heating was used to improve mechanical properties of elastic hinges by the reduction of material degradation due to high shear rates. To verify the change of shear rates, selective induction heating simulation and injection molding simulations were performed. The linear relation between mold temperature and maximum shear rate in the cross-section was identified and the mechanical tests showed significant differences in hinge stiffness, tensile strength and elongation at break.

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Warpage Optimisation on the Moulded Part with Straight Drilled and Conformal Cooling Channels Using Response Surface Methodology (RSM), Glowworm Swarm Optimisation (GSO) and Genetic Algorithm (GA) Optimisation Approaches

Cited by 17 publications

References 41 publications

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Development of an Epoxy-Based Rapid Tool with Low Vulcanization Energy Consumption Channels for Liquid Silicone Rubber Injection Molding

Comparison of Conventional and Conformal Cooling Channels in the Production of a Commercial Injection-Moulded Component

Application of Selective Induction Heating for Improvement of Mechanical Properties of Elastic Hinges

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