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Metal Additive Manufacturing of Plastic Injection Molds with Conformal Cooling Channels

Authors: Kanbur, Baris Burak; Zhou, Yi; Shen, Suping; Wong, Kim Hai; Chen, Charles; Shocket, Abe; Duan, Fei;

Metal Additive Manufacturing of Plastic Injection Molds with Conformal Cooling Channels

Abstract

Conformal cooling channels (CCCs) are widely used in the plastic injection molding process to improve the product quality and operational performance. Tooling that incorporates CCCs can be fabricated through metal additive manufacturing (MAM). The present work focuses on the MAM of a plastic injection mold insert with different CCC types that are circular, serpentine, and tapered channels with/without body-centered cubic (BCC) lattices. The entire manufacturing process of the mold insert is explained from the design step to the final printing step including the computational thermal & mechanical simulations, performance assessments, and multiobjective optimization. Compared to the traditional channels, conformal cooling channels achieved up to 62.9% better cooling performance with a better thermal uniformity on the mold surface. The optimum mold geometry is decided using the multiobjective optimization procedure according to the multiple objectives of cooling time, temperature non-uniformity, and pressure drop in the channel. Direct Metal Laser Sintering (DMLS) method is used for manufacturing the molds and the quality of the printed molds are analyzed with the X-ray Computed Tomography (X-ray CT) technique. The errors between the design and the printed parameters are less than 5% for the circular and tapered channels while the maximum deviation of the strut diameters of the BCC is 0.06 mm.

Country
Singapore
Keywords

Metal Additive Manufacturing, 3D Printing, metal additive manufacturing; 3D printing; computer-aided engineering; computer-aided design; conformal cooling; heat transfer; conjugate heat transfer; Direct Metal Laser Sintering; multiobjective optimization; plastic injection, Engineering::Mechanical engineering, :Mechanical engineering [Engineering], Article, 620

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
58
Top 1%
Top 10%
Top 1%
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