Conformal Cooling Versus Conventional Cooling: An Injection Molding Case Study With P-20 and 3DP™-Processed Tooling

2000 ◽  
Vol 625 ◽  
Author(s):  
Wayde R. Schmidt ◽  
Ronald D. White ◽  
Connie E. Bird ◽  
Joseph V. Bak
Keyword(s):  
Injection Molding ◽  
Design Approach ◽  
Mold Design ◽  
Simulation Tool ◽  
Conformal Cooling ◽  
Designed Experiments ◽  
Tool Fabrication ◽  
Conventional Cooling

AbstractA series of designed experiments was performed in an attempt to evaluate and quantify the historically “anecdotal” benefits of conformal cooling for injection molding tooling. The study considered different generic part geometries, gating schemes, mold materials, plastic resins and cooling approaches. This paper provides an overview of the mold design approach, cooling simulation, tool fabrication via the 3DP™ process, as well as part molding and inspection results.

scholarly journals Design, Optimization and Validation of Conformal Cooling Technique for Additively Manufactured Mold Insert

2021 ◽  
Vol 2070 (1) ◽  
pp. 012225
Author(s):  
G.Dongre Ganesh ◽  
S.Chaitanya Sarang ◽  
M.Jonnalagadda Sai
Keyword(s):  
Injection Molding ◽  
Mold Insert ◽  
Cooling Time ◽  
Cyclic Process ◽  
Conformal Cooling ◽  
Cooling Circuit ◽  
Cycle Times ◽  
Cooling Channels ◽  
Conventional Cooling ◽  
Time Required

Abstract Injection molding is a cyclic process comprising of cooling phase as the largest part of this cycle. Providing efficient cooling in lesser cycle times is of significant importance in the molding industry. Conformal cooling is a proven technique for reduction in cycle times for injection molding. In this study, we have replaced a conventional cooling circuit with an optimized conformal cooling circuit in an injection molding tool (mold). The required heat transfer rate, coolant flow rate and diameter of channel was analytically calculated. Hybrid Laser powder bed fusion technique was used to manufacture this mold tool with conformal channels. The material used for manufacturing mold was maraging steel (M300). Thermal efficiency of the conformal channels was experimentally calculated using thermal imaging. Autodesk MoldFlow software was used to simulate and predict the cooling time required using conformal cooling channels. The results showed a decrease in cooling time and increase in cooling efficiency with the help of conformal cooling in additively manufactured mold insert.

scholarly journals Adaptive Conformal Cooling of Injection Molds Using Additively Manufactured TPMS Structures

Polymers ◽  
2022 ◽  
Vol 14 (1) ◽  
pp. 181
Author(s):  
Seo-Hyeon Oh ◽  
Jong-Wook Ha ◽  
Keun Park
Keyword(s):  
Injection Molding ◽  
Design Parameters ◽  
Mold Surface ◽  
Heated Region ◽  
Digital Light Processing ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Periodic Minimal Surface ◽  
Triply Periodic Minimal Surface ◽  
Conventional Cooling

In injection molding, cooling channels are usually manufactured with a straight shape, and thus have low cooling efficiency for a curved mold. Recently, additive manufacturing (AM) was used to fabricate conformal cooling channels that could maintain a consistent distance from the curved surface of the mold. Because this conformal cooling channel was designed to obtain a uniform temperature on the mold surface, it could not efficiently cool locally heated regions (hot spots). This study developed an adaptive conformal cooling method that supports localized-yet-uniform cooling for the heated region by employing micro-cellular cooling structures instead of the typical cooling channels. An injection molding simulation was conducted to predict the locally heated region, and a mold core was designed to include a triply periodic minimal surface (TPMS) structure near the heated region. Two biomimetic TPMS structures, Schwarz-diamond and gyroid structures, were designed and fabricated using a digital light processing (DLP)-type polymer AM process. Various design parameters of the TPMS structures, the TPMS shapes and base coordinates, were investigated in terms of the conformal cooling performance. The mold core with the best TPMS design was fabricated using a powder-bed fusion (PBF)-type metal AM process, and injection molding experiments were conducted using the additively manufactured mold core. The developed mold with TPMS cooling achieved a 15 s cooling time to satisfy the dimensional tolerance, which corresponds to a 40% reduction in comparison with that of the conventional cooling (25 s).

Teaching Computing in a Multidisciplinary Way in Social Studies Classes in School – A Case Study

2017 ◽  
Vol 1 (2) ◽  
pp. 3 ◽  
Author(s):  
Christiane Gresse Von Wangenheim ◽  
Nathalia Cruz Alves ◽  
Pedro Eurico Rodrigues ◽  
Jean Carlo Hauck
Keyword(s):  
Instructional Design ◽  
Social Studies ◽  
21St Century ◽  
Multidisciplinary Approach ◽  
Design Approach ◽  
Instructional Unit ◽  
Computing Education ◽  
Interest And Motivation

In order to be well-educated citizens in the 21st century, children need to learn computing in school. However, implementing computing education in schools faces several practical problems, such as lack of computing teachers and time in an already overloaded curriculum. A solution can be a multidisciplinary approach, integrating computing education within other subjects in the curriculum. The present study proposes an instructional unit for computing education in social studies classes, with students learning basic computing concepts by programming history related games using Scratch. The instructional unit is developed following an instructional design approach and is applied and evaluated through a case study in four classes (5th and 7th grade) with a total of 105 students at a school in (omitted for submission). Results provide a first indication that the instructional unit enables the learning of basic computing concepts (specifically programming) in an efficient, effective and entertaining way increasing also the interest and motivation of students to learn computing.

scholarly journals Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Polymers ◽  
2021 ◽  
Vol 13 (8) ◽  
pp. 1224
Author(s):  
Chil-Chyuan Kuo ◽  
Wei-Hua Chen
Keyword(s):  
Thermal Conductivity ◽  
Injection Molding ◽  
Cooling Time ◽  
Performance Ratio ◽  
Cooling Efficiency ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Fused Deposition ◽  
Silicone Rubber Mold

Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

scholarly journals BRINGING SYSTEMIC DESIGN IN THE EDUCATIONAL PRACTICE: THE CASE OF GENDER EQUALITY IN AN ACADEMIC CONTEXT

2021 ◽  
Vol 1 ◽  
pp. 581-590
Author(s):  
Alexis JP Jacoby ◽  
Kristel Van Ael
Keyword(s):  
Gender Inequality ◽  
Design Education ◽  
Educational Practice ◽  
Design Approach ◽  
Academic Context ◽  
Traditional Design ◽  
Systemic Problems ◽  
Societal Problems ◽  
Systemic Design

AbstractThe field of design practice and design education is reaching out to address problems that cannot be solved by introducing a single product or service. Complex societal problems such as gender inequality cannot be solved using a traditional problem-solving oriented design approach. The specific characteristics of these problems require new ways of dealing with the dynamics, scale and complexity of the problem.Systemic design is a design approach integrating systems thinking in combination with more traditional design methodologies, addressing complex and systemic problems. This paper reports a systemic design approach in an educational context for the case of academic gender inequality. We show the way the problem was addressed and how design students were invited to take a systemic perspective, provide integrated interventions and take first steps in providing instruments for implementation. We conclude with the learnings from this case study, both on the process and the results.

Investigation of a passive design approach for a building facility: a case study

2021 ◽  
pp. 1-19
Author(s):  
Dusan Randjelovic ◽  
Miomir Vasov ◽  
Marko Ignjatovic ◽  
Mirko Stojiljkovic ◽  
Veliborka Bogdanovic
Keyword(s):  
Design Approach ◽  
Passive Design
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