Cycle Time Reduction in Injection Molding by Using Milled Groove Conformal Cooling

This paper presents simulation study on Milled Grooved conformal cooling channels(MGCCC)in injection molding.MGCCC has a more effective cooling surface area which helps to provide efficient cooling as compared to conventional cooling.A case study of Encloser part is investigated for cycle time reduction and quality improvement.The performance designs of straight drilled are compared with MGCCC by using Autodesk Moldflow Insight(AMI)2016.The results show total 32.1% reduction of cooling time and 9.86% reduction of warpage in case of MGCCC as compared to conventional cooling.

Effect of Different Shapes of Conformal Cooling Channel on the Parameters of Injection Molding

Cooling system improvement is important in injection molding to get betterquality and productivity. The aim of this paper was to compare the different shapes of theconformal cooling channels (CCC) with constant surface area and CCC with constantvolume in injection molding using Mold-flow Insight 2016 software. Also the CCC resultswere compared with conventional cooling channels. Four different shapes of the CCC suchas circular, elliptical, rectangular and semi-circular were proposed. The locations of thecooling channels were also kept constant. The results in terms of cooling time, cycle timereduction and improvement in quality of the product shows that no significant effect ofCCC’s shapes when surface area of CCC kept constant. On the other hand, the rectangularCCC shows better result as compared to other shapes of CCC when volume of CCC werekept constant.

Corrosion Behavior of the S136 Mold Steel Fabricated by Selective Laser Melting

The selective laser melting(SLM) method has a great potential for fabricating injection mold with complex structure. However, the microstructure and performance of the SLM molds show significantly di erent from those manufac?tured by traditional technologies. In this study, the microstructure, hardness and especially corrosion behavior of the samples fabricated by SLM and casting were investigated. The XRD results exhibit that the γ?Fe phase is only obtained in the SLM parts, and the α?Fe peak slightly moves to low di raction angle compared with casting counterparts. Due to the rapid cooling rate, the SLM samples have fine cellular microstructures while the casting ones have coarse grains with obvious elements segregation. Besides, the SLM samples show anisotropy, hardness of side view and top view are 48.73 and 50.31 HRC respectively, which are 20% higher than that of casting ones. Corrosion results show that the SLM samples have the better anti?corrosion resistance(in a 6% FeCl3 solution for 48 h) but the deeper corrosion pits than casting ones. Finally, the performance of the SLM molds could meet the requirement of injecting production. Moreover, the molds especially present a significant decrease(20%) of cooling time and increases of cooling uniform?ity due to the customized conformal cooling channels.

Finite Element Analysis on the Injection Molding and Productivity of Conformal Cooling Channel

The study proves that the conformal cooling channel can overcome the disadvantages of the conventional cooling channel resulting from the limitation in complicated shape.The simulation analyses of the fragrance lamp with different cooling layouts show that the conformal cooling channel can offer a more uniform heat dissipation,lower volume shrinkage and shorter time to freeze than the conventional channel,which indicates significantly improvements in productivity and quality.

Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion

Conformal cooling coils have been developed during the last decades through the use of additive manufacturing(AM)technologies.The main goal of this study was to analyze how the presence of an internal channel that could act as a conformal cooling coil could affect compressive strength and quasi-elastic gradient of AlSi10Mg lattice structures produced by laser powder bed fusion(LPBF).Three different configurations of samples were tested in compression at 25℃ and 200℃.The reference structures were body centered cubic(BBC)in the core of the samples with vertical struts along Z(BCCZ)lattices in the outer perimeter,labelled as NC samples.The main novelty consisted in inserting a straight elliptical channel and a 45°elliptical channel inside the BCCZ lattice structures,labelled as SC and 45C samples respectively.All the samples were then tested in as-built(AB)condition,and after two post process heat treatments,commonly used for AlSi10Mg LPBF industrial components,a stress relieving(SR)and a T6 treatment.NC lattice structures AB exhibited an overall fragile fracture and therefore the SC and 45C configuration samples were tested only after thermal treatments.The test at 25℃ showed that all types of samples were characterized by negligible variations in their quasi-elastic gradients and yield strength.On the contrary,the general trend of stress-strain curves was influenced by the presence of the channel and its position.The test at 200℃ showed that NC,SC and 45C samples after SR and T6 treatments exhibited a metal-foam like deformation.