scholarly journals Use of Maraging Steel 1.2709 for Implementing Parts of Pressure Mold Devices with Conformal Cooling System

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5533
Author(s):  
Jarosław Piekło ◽  
Aldona Garbacz-Klempka
Keyword(s):  
Cooling System ◽  
Casting Machine ◽  
Steel Powder ◽  
Experimental Tests ◽  
Test Material ◽  
Conformal Cooling ◽  
Temperature Changes ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Conventional Solution

In this paper, we present the results of experimental tests and numerical calculations for parts of foundry mold devices made by selective laser melting (SLM). The main aim of this research was to compare the heat conduction efficiency of the conformal and the traditional channel arrangement. The infusion spreader with a conformal channel arrangement and the test material were made with an M2 Concept Laser Cusing machine using 1.2709 steel powder. Temperature changes in the spreaders were compared between conventional and conformal cooling channels using finite element method (FEM) calculations. The position of the so-called “thermal equilibrium isotherm” was determined for both sprue spreaders, which separate the area of the mold with a constant temperature from the zone of cyclic temperature changes. The components of the sprue spreaders in a stress state caused by temperature changes during the operation of the pressure machine were determined using the FEM model. It was found that the cooling system shortened the time of solidification and cooling of the alloy. Based on the analysis of the strength test results and the fracture surface of the samples, the relationship between heat treatment parameters and the strength, hardness, and elongation of the tested material was determined. The sprue spreaders were installed under a pressure machine and tested under production conditions. The use of a sprue spreader with a conformal cooling system shortened the time of a single cycle of the casting machine compared to the conventional solution.

scholarly journals A methodology for mould conformal cooling channels optimization exploiting 3D printing

2021 ◽  
Author(s):  
Edoardo Battista Arrivabeni ◽  
Daniele Tomasoni ◽  
Luca Giorleo ◽  
Maurizio Claudio Barbato
Keyword(s):  
3D Printing ◽  
Design Procedure ◽  
Optimization Procedure ◽  
Experimental Tests ◽  
Conformal Cooling ◽  
Testing Procedures ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Push Forward ◽  
3D Printed

With the advent of 3D printing, it is now possible to produce any part or system with an approach than makes design much deeply interlaced with production. In this scenario, CAE has gained power thanks to the possibility of thinking and then manufacture ideas that go well beyond what was possible in the past. This design approach is perfectly suitable to push forward mould conformal cooling performance. In this work, a coupling of CAD, CFD and 3D printing supported by experimental tests was applied to define a design procedure for conformal cooling channels. In particular, cooling channels for a mould were engineered via CAD, then tested via CFD and, after an initial optimization procedure, the chosen design was 3D printed in specimens suitable to be mounted on a heat exchanger (HX) experimental test rig that was especially adapted for the scope. Fluids temperature, volume flow rates and heat transfer performance were measured. A feedback loop was considered to link measurements and channels redesign. Results together with design and testing procedures are reported and commented.

scholarly journals Application of New Triple Hook-Shaped Conformal Cooling Channels for Cores and Sliders in Injection Molding to Reduce Residual Stress and Warping in Complex Plastic Optical Parts

Polymers ◽  
2021 ◽  
Vol 13 (17) ◽  
pp. 2944
Author(s):  
Abelardo Torres-Alba ◽  
Jorge Manuel Mercado-Colmenero ◽  
Juan de Dios Caballero-Garcia ◽  
Cristina Martin-Doñate
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cooling System ◽  
Plastic Part ◽  
Correct Operation ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Geometric Conditions ◽  
Optical Part ◽  
Conformal Cooling Channels

The paper presents a new design of a triple hook-shaped conformal cooling channels for application in optical parts of great thickness, deep cores, and high dimensional and optical requirements. In these cases, the small dimensions of the core and the high requirements regarding warping and residual stresses prevent the use of traditional and standard conformal cooling channels. The research combines the use of a new triple hook-shaped conformal cooling system with the use of three independent conformal cooling sub-systems adapted to the complex geometric conditions of the sliders that completely surround the optical part under study. Finally, the new proposed conformal cooling design is complemented with a small insert manufactured with a new Fastcool material located in the internal area of the optical part beside the optical facets. A transient numerical analysis validates the set of improvements of the new proposed conformal cooling system presented. The results show an upgrade in thermal efficiency of 267.10% in comparison with the traditional solution. The increase in uniformity in the temperature gradient of the surface of the plastic part causes an enhancement in the field of displacement and in the map of residual stresses reducing the total maximum displacements by 36.343% and the Von—Mises maximum residual stress by 69.280% in comparison with the results obtained for the traditional cooling system. Additionally, the new design of cooling presented in this paper reduces the cycle time of the plastic part under study by 32.61%, compared to the traditional cooling geometry. This fact causes a very high economic and energy saving in line with the sustainability of a green mold. The improvement obtained in the technological parameters will make it possible to achieve the optical and functional requirements established for the correct operation of complex optical parts, where it is not possible to use traditional cooling channels or standard conformal cooling layouts.

Defect Minimization of an Injection Molded Plastic Component Using Conformal Cooling Channels

2021 ◽  
Vol 1019 ◽  
pp. 205-210
Author(s):  
Deepika S. Singraur ◽  
Bhushan T. Patil ◽  
Vasim A. Shaikh
Keyword(s):  
Performance Parameters ◽  
Cooling Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Molded Part ◽  
Cooling Method ◽  
Conformal Cooling Channels ◽  
Differential Shrinkage ◽  
Injection Molded ◽  
Injection Molded Plastic

The cooling process is an essential aspect while designing for uniform heat transfer between the mold and the molded part. Improper design and placement of cooling channels result in non-uniform cooling and thus results in differential shrinkage and warpage on the final product. The installation of the channels yet plays a crucial role in the cooling of the part. Conforming channels that are placed at an optimum distance from the part to enhance the cooling process. In this paper, the performance parameters of straight drilled channels are compared with the conformal cooling channels for an electric alarm box. The analysis indicates that the conformal cooling method improved and enhanced the cooling process and reduced the defects like warpage and differential shrinkage by 25.5% and 28.0% respectively.

Sign in / Sign up

Export Citation Format

Share Document