Improving the Quality and Productivity of Molded Parts with a New Design of Conformal Cooling Channels for the Injection Molding Process

2015 ◽  
Vol 35 (1) ◽  
Author(s):  
Shayfull Zamree Abd Rahim ◽  
S. Sharif ◽  
Azlan Mohd Zain ◽  
S. M. Nasir ◽  
R. Mohd Saad
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Molded Parts

Warpage Analysis with Straight Drilled and Conformal Cooling Channels on Front Panel Housing by Using Taguchi Method

2013 ◽  
Vol 594-595 ◽  
pp. 593-603 ◽  
Author(s):  
Z. Shayfull ◽  
S. Sharif ◽  
Azlan Mohd Zain ◽  
R. Mohd Saad ◽  
M.A. Fairuz
Keyword(s):  
Taguchi Method ◽  
Front Panel ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Thermal Distribution ◽  
Conformal Cooling Channels ◽  
Molded Parts ◽  
Differential Shrinkage

The challenging in injection molding process is to get the uniform thermal distribution on the molded parts during the cooling stage which is mainly depend on the design of the cooling channels in injection mold. Poor design of cooling channels will result a non-uniform thermal distribution which lead to a longer cycle time, differential shrinkage and warpage defects on the molded parts. In this study, the performance of conformal cooling channels compared to the straight drilled cooling channels in order to minimize the warpage on the front panel housing is evaluated. The simulation results from Autodesk Moldflow Insight (AMI) 2013 are analyzed by using Taguchi Method and Analysis of Variance (ANOVA). The analyses show that conformal cooling channels are able to improve the quality of the molded parts in term of warpage compared to the conventional straight drilled cooling channels and the results are beneficial for the molding industries which involving the precise parts.

scholarly journals Structural Analysis of Molds with Conformal Cooling Channels: A Numerical Study

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
Tiago Noversa ◽  
Hugo Rodrigues ◽  
Leandro Fernandes ◽  
António Pontes
Keyword(s):  
Injection Molding ◽  
Thermal Stresses ◽  
Numerical Study ◽  
Operating Conditions ◽  
Maximum Pressure ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

Abstract The manufacturing of Conformal cooling channels (CCC’s) is now easier and more affordable, owing to the recent developments in the field of additive manufacturing. The use of CCC’s allows better cooling performances than the conventional (straight-drilled) channels, in the injection molding process. The main reason is that CCC’s can follow the pathways of the molded geometry, while the conventional channels, manufactured by traditional machining techniques, are not able to. Using CCCs can significantly improve the cycle time, allow to obtain a more uniform temperature distribution, and reduce thermal stresses and warpage. However, the design process for CCC is more complex than for conventional channels. Computer-aided engineering (CAE) simulations are important for achieving effective and affordable design. This article presents important results regarding molds with new conformal cooling channels geometries. The aim is to assess the maximum pressure that the parts can be subjected to in a real injection molding application. Linear structural analyses are carried over in the Finite Element Method Software ANSYS Workbench 2020 R2, in order to analyze both the resistance and stiffness behavior of the studied geometries. The results are analyzed according to several metrics. The results were discussed and it could be concluded that some of the structures are suitable for the typical operating conditions of the injection molding process.

scholarly journals Dynamic conformal cooling improves injection molding

2021 ◽  
Vol 114 (1-2) ◽  
pp. 107-116
Author(s):  
Andreas Kirchheim ◽  
Yogeshkumar Katrodiya ◽  
Livia Zumofen ◽  
Frank Ehrig ◽  
Curdin Wick
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Injection Molding Process ◽  
Layer By Layer ◽  
Mold Surface ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Heating And Cooling ◽  
Conformal Cooling Channels

AbstractTo achieve a certain visual quality or acceptable surface appearance in injection-molded components, a higher mold surface temperature is needed. In order to achieve this, injection molds can be dynamically tempered by integrating an active heating and cooling process inside the mold halves. This heating and cooling of the mold halves becomes more efficient when the temperature change occurs closer to the mold surface. Complex channels that carry cold or hot liquids can be manufactured close to the mold surface by using the layer by layer principle of additive manufacturing. Laser powder bed fusion (L-PBF), as an additive manufacturing process, has special advantages; in particular, so-called hybrid tools can be manufactured. For example, complex tool inserts with conformal cooling channels can be additively built on simple, machined baseplates. This paper outlines the thermal simulation carried out to optimize the injection molding process by use of dynamic conformal cooling. Based on the results of this simulation, a mold with conformal cooling channels was designed and additively manufactured in maraging steel (1.2709) and then experimentally tested.

Improving Warpage with Milled Groove Square Shape Conformal Cooling Channels

2016 ◽  
Vol 700 ◽  
pp. 31-41
Author(s):  
Z. Shayfull ◽  
S. Sharif ◽  
Azlan Mohd Zain ◽  
S.M. Nasir ◽  
R. Mohd Saad
Keyword(s):  
Injection Moulding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Cross Sectional ◽  
Conformal Cooling ◽  
Moulding Process ◽  
Cooling Channels ◽  
Thermal Distribution ◽  
Conformal Cooling Channels ◽  
Injection Moulding Process

Warpage is a common issue in an injection moulding process due to non-uniform temperature variation causing differential shrinkage on the moulded parts. In designing moulds for injection molding process, it is very difficult to achieve efficient cooling with uniform thermal distribution. Most of researchers focus on an optimisation of processing parameters to improve the warpage. However, the conformal cooling channels have advantages with the uniform distance between center of cooling channels and mould surfaces in order to get a better thermal distribution thus reducing the warpage. This paper presents the Milled Grooved Square Shape (MGSS) conformal cooling channels which provide more uniform in cooling and have a bigger effective cooling surface area cross sectional area and comparing to circular and others type of cooling channels with similar cross section. A case study on front panel housing is investigated and the possibility of fabrication the conformal cooling channels on hard tooling for injection moulding process which is easier to design, fabricate and assemble compared to other method are presented. The performance designs of straight drilled are compared to the two types of MGSS conformal cooling channels by using Autodesk Moldflow Insight (AMI) 2012. The analyses show that the both types of MGSS conformal cooling channel suggested can provide a more uniform thermal distribution and able to reduce the warpage on the molded part compared to the straight drilled cooling channels.

scholarly journals 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

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1326
Author(s):  
Mohd Hazwan Mohd Hanid ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Safian Sharif ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Acrylonitrile Butadiene Styrene ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

It is quite challenging to control both quality and productivity of products produced using injection molding process. Although many previous researchers have used different types of optimisation approaches to obtain the best configuration of parameters setting to control the quality of the molded part, optimisation approaches in maximising the performance of cooling channels to enhance the process productivity by decreasing the mould cycle time remain lacking. In this study, optimisation approaches namely Response Surface Methodology (RSM), Genetic Algorithm (GA) and Glowworm Swarm Optimisation (GSO) were employed on front panel housing moulded using Acrylonitrile Butadiene Styrene (ABS). Each optimisation method was analysed for both straight drilled and Milled Groove Square Shape (MGSS) conformal cooling channel moulds. Results from experimental works showed that, the performance of MGSS conformal cooling channels could be enhanced by employing the optimisation approach. Therefore, this research provides useful scientific knowledge and an alternative solution for the plastic injection moulding industry to improve the quality of moulded parts in terms of deformation using the proposed optimisation approaches in the used of conformal cooling channels mould.

Robust Parameter Design of the Precision Injection Molding Process

1994 ◽  
Author(s):  
Sornkrit Leartcheongchowasak ◽  
Merwan Mehta ◽  
Hamid Al-Kadi ◽  
Keith Sequeira ◽  
Brian Snow ◽  
...  
Keyword(s):  
Injection Molding ◽  
Taguchi Methods ◽  
Injection Molding Process ◽  
Robust Parameter Design ◽  
Molding Process ◽  
Product Lines ◽  
Molded Parts ◽  
Robust Parameter ◽  
Independent Process ◽  
The Right

Abstract The most important problem, causing defective parts, in the injection molding process, is nonuniform shrinkage of molded parts. This leads to an iterative trial-and-error cycles of modification of mold cavity and core to arrive at the right dimensional size required which can occasionally to complete retooling. For this process, there are many factors that can be thrown out of control. Using the traditional scientific approach, engineers have longed to understand the mechanics of the process to control it, with limited success. In this paper, a design of experiments setup, using the Taguchi Methods, was done to reduce the nonuniform shrinkage. The company where the experiment was carried out is a precision parts molder for their own product lines. By using the internal experts from the company, a list of independent process parameters with no interactions which were thought the most responsible for dimensional size were listed. As there were 13 such parameters, it was decided to use the L27 orthogonal array. The optimum value that the company experts thought would produce the right part were used as the settings for the initial experiment. The 27 experiments were then performed, allowing sufficient time to let the machine stabilized between the experiments. The S/N ratio calculation for 27 experiments was explained. Next the calculations for the percentage that each parameter contributes to the dimension was determined. Finally, a confirmation experiment was performed to verify the results.

scholarly journals Electricity Consumption Estimation of the Polymer Material Injection-Molding Manufacturing Process: Empirical Model and Application

Materials ◽  
2018 ◽  
Vol 11 (9) ◽  
pp. 1740 ◽  
Author(s):  
Ana Elduque ◽  
Daniel Elduque ◽  
Carmelo Pina ◽  
Isabel Clavería ◽  
Carlos Javierre
Keyword(s):  
Environmental Impact ◽  
Injection Molding ◽  
Empirical Model ◽  
Electricity Consumption ◽  
Injection Molding Process ◽  
Molding Process ◽  
Polymer Injection ◽  
Wide Range ◽  
Molded Parts ◽  
Polymer Injection Molding

Polymer injection-molding is one of the most used manufacturing processes for the production of plastic products. Its electricity consumption highly influences its cost as well as its environmental impact. Reducing these factors is one of the challenges that material science and production engineering face today. However, there is currently a lack of data regarding electricity consumption values for injection-molding, which leads to significant errors due to the inherent high variability of injection-molding and its configurations. In this paper, an empirical model is proposed to better estimate the electricity consumption and the environmental impact of the injection-molding process. This empirical model was created after measuring the electricity consumption of a wide range of parts. It provides a method to estimate both electricity consumption and environmental impact, taking into account characteristics of both the molded parts and the molding machine. A case study of an induction cooktop housing is presented, showing adequate accuracy of the empirical model and the importance of proper machine selection to reduce cost, electricity consumption, and environmental impact.

Study on Improving the Life of Stereolithography Injection Mold

2012 ◽  
Vol 468-471 ◽  
pp. 1013-1016 ◽  
Author(s):  
Hua Qing Lai
Keyword(s):  
Injection Molding ◽  
Injection Molding Process ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Plastic Parts ◽  
Assembly Operations ◽  
Conventional Injection Molding ◽  
Shape And Size

Molding is one of the most versatile and important processes for manufacturing complex plastic parts. It is a method of fabricating plastic parts by utilizing a mold or cavity that has a shape and size similar to the part being produced. Molten polymer is injected into the cavity, resulting in the desired part upon solidification. The injection-molded parts typically have excellent dimensional tolerance and require almost no finishing and assembly operations. But new variations and emerging innovations of conventional injection molding have been continuously developed to offer special features and benefits that cannot be accomplished by the conventional injection molding process. This study aims to improving the life of stereolithography injection mold.

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