scholarly journals A Simple Method of Reducing Coolant Leakage for Direct Metal Printed Injection Mold with Conformal Cooling Channels Using General Process Parameters and Heat Treatment

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7258
Author(s):  
Chil-Chyuan Kuo ◽  
Shao-Xuan Qiu
Keyword(s):  
Process Parameters ◽  
Injection Mold ◽  
Simple Method ◽  
General Process ◽  
Conformal Cooling ◽  
Cooling Stage ◽  
Cooling Channels ◽  
Metal Printing ◽  
Conformal Cooling Channels ◽  
Wax Injection

Direct metal printing is a promising technique for manufacturing injection molds with complex conformal cooling channels from maraging steel powder, which is widely applied in automotive or aerospace industries. However, two major disadvantages of direct metal printing are the narrow process window and length of time consumed. The fabrication of high-density injection molds is frequently applied to prevent coolant leakage during the cooling stage. In this study, we propose a simple method of reducing coolant leakage for a direct-metal-printed injection mold with conformal cooling channels by combining injection mold fabrication with general process parameters, as well as solution and aging treatment (SAT). This study comprehensively investigates the microstructural evolution of the injection mold after SAT using field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. We found that the surface hardness of the injection mold was enhanced from HV 189 to HV 546 as the Ni-Mo precipitates increased from 12.8 to 18.5%. The size of the pores was reduced significantly due to iron oxide precipitates because the relative density of the injection mold increased from 99.18 to 99.72%. The total production time of the wax injection mold without coolant leakage during the cooling stage was only 62% that of the production time of the wax injection mold fabricated with high-density process parameters. A significant savings of up to 46% of the production cost of the injection mold was obtained.

scholarly journals Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

2019 ◽  
Vol 9 (20) ◽  
pp. 4341 ◽  
Author(s):  
Chen-Yuan Chung
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Process Parameters ◽  
Large Diameter ◽  
Melt Temperature ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Highly Efficient ◽  
Conformal Cooling Channels ◽  
Filling Time

Plastic lenses are light and can be mass-produced. Large-diameter aspheric plastic lenses play a substantial role in the optical industry. Injection molding is a popular technology for plastic optical manufacturing because it can achieve a high production rate. Highly efficient cooling channels are required for obtaining a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, highly efficient three-dimensional spiral channels can be realized for conformal cooling technique. However, the design of conformal cooling channels is very complex and requires optimization analyses. In this study, finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels. According to the simulation results, the use of conformal cooling channels can reduce the surface temperature difference of the melt, ejection time, and warpage. Moreover, the optimal process parameters (such as melt temperature, mold temperature, filling time, and packing time) obtained from the design of experiments improved the fringe pattern and eliminated the local variation of birefringence. Thus, this study indicates how the optical properties of plastic lenses can be improved. The major contribution of present proposed methods can be applied to a mold core containing the conformal cooling channels by metal additive manufacturing.

Characterization of a direct metal printed injection mold with different conformal cooling channels

2020 ◽  
Vol 107 (3-4) ◽  
pp. 1223-1238
Author(s):  
Chil-Chyuan Kuo ◽  
Zi-Fan Jiang ◽  
Xin-Yi Yang ◽  
Shao-Xuan Chu ◽  
Jia-Qi Wu
Keyword(s):  
Injection Mold ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

Analysis and Manufacturing of Conformal Cooling Channels in Injection Mold

2014 ◽  
Vol 651-653 ◽  
pp. 630-633 ◽  
Author(s):  
Guo Qiang Gao ◽  
Yu Shan Liu ◽  
Yu Jun Cai
Keyword(s):  
Simulation Analysis ◽  
Three Dimensional ◽  
Injection Mold ◽  
Conformal Cooling ◽  
Three Dimensional Printing ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
The Difference ◽  
Conventional Cooling ◽  
Dimensional Printing

In view of the cooling difficulty in complex injection mold, the difference between conventional cooling channels and Conformal Cooling Channels (CCC) is researched. CCC is superior to conventional cooling channels on cooling effect according to the simulation analysis of plastic flow based on Autodesk Moldflow Insight software. Considered the manufacturing difficulty of CCC, an approach which uses three-dimensional printing and investment casting is put forward in the end.

Study on the Optimization of Conformal Cooling Channels for Plastic Injection Mold

2012 ◽  
Vol 591-593 ◽  
pp. 502-506
Author(s):  
Ying Ping Qian ◽  
Yong Wang ◽  
Ju Hua Huang ◽  
Xi Zhi Zhou
Keyword(s):  
Injection Mold ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Complicated Process ◽  
Molded Parts ◽  
Injection Molded ◽  
Popular Subject ◽  
Plastic Injection

The cooling process of injection molding is a complicated process related to thermodynamics and hydrodynamics, and it has a direct impact on quality and productivity of injection molded parts. With increasing requirements on high quality of injection molded parts, the research on the design of conformal cooling channels of injection mould gradually becomes a popular subject. The paper introduced the process of heat transfer for plastic injection mold with conformal cooling channels and its feature; analysed the optimization of conformal cooling channels; A new set of design methodology and rules is developed.

Manufacture of Production Quality Injection Mold Tools Using SLS and HSM

2007 ◽  
Author(s):  
C. M. Taylor ◽  
I. P. Ilyas ◽  
K. W. Dalgarno ◽  
J. Gosden
Keyword(s):  
Case Studies ◽  
Rapid Manufacturing ◽  
Injection Mold ◽  
Metal Composite ◽  
Injection Mould ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Near Net Shape ◽  
The Impact

The use of a rapid manufacturing method to create injection mould tools offers the opportunity to create conformal cooling channels in the core/cavity inserts. Conformal cooling channels allow for better thermal management of the injection mold tool through the cycle, with the potential to reduce cycle times and/or improve product quality. However, currently available rapid manufacturing methods do not deliver the levels of accuracy and surface finish required to meet typical injection mould tool specifications. This paper reports on a hybrid approach to developing the mold inserts, which uses the rapid manufacturing process of indirect selective laser sintering (SLS), using the 3D Systems LaserForm process, to create a near net shape insert with conformal cooling channels, and then produces the net shape inserts by using high speed machining (HSM) as a finishing process. This approach to injection mold tool development has been tested through three industrial case studies. In each study existing injection mold inserts have been redesigned to give a conformally cooled tool. These have then been manufactured to near net shape in a steel/bronze metal composite through indirect SLS, and finished to production specification using HSM, EDM and polishing. Within the case studies the main aim has been to improve productivity, and the inserts have been evaluated in industrial trials in order to assess their performance in terms of cycle time, energy usage, durability and quality. The results show that significant productivity improvements and energy use reductions in injection molding are possible through the implementation of conformal cooling. Consistency of part quality and material durability have been assessed through extended molding trials, and in some cases there is a clear economic benefit to using the inserts. However, the importance of up front modelling to understand the impact of conformal cooling channels, the need for careful planning in manufacture to ensure that the required internal geometry is created, and the need for multiple representations of the required geometry to inform the different stages of the manufacture process are highlighted.

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