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Optimization of cooling channels in plastic injection molding process: conventional straight-drilled cooling system vs conformal cooling system

Authors: Reis, Gabriel Fernandes dos;

Optimization of cooling channels in plastic injection molding process: conventional straight-drilled cooling system vs conformal cooling system

Abstract

The optimization of the cooling system of a mold from the company COPEFI was carried out to improve the warpage of the parts. First, an optimization of the process parameters was performed using the mold in production. A comparison between simulated and experimental work was made with the intend to validate the simulation method. Afterwards, a new design, using conventional straight-drilled channels, was performed, and studied utilizing simulation software (Moldex3D). Finally, a new design, using conformal cooling channels, was performed, and evaluated resorting to simulation software. To improve warpage, the process parameters chosen were: A – Mold Temperature, B – Injection Temperature, C – Injection Speed, D- Holding Pressure Time and E – Cooling Time. Regarding to the design optimization, the parameters chosen were: A – Diameter, B – Distance between cooling channels, C – Distance between cooling channels and the part, D – Mold material and E – Number of circuits. In both cases, Taguchi’s orthogonal array was used as the Design of experiments (DOE) tool. An orthogonal array of L16 (215) was performed for all the simulated models and an orthogonal array of L8 (27) was used for the experimental work. Analysis of Variance was performed to find the contribution of the processing parameters on the improvement of warpage. Globally it was found a strong contribution of cooling time and injection temperature on process parameters optimization. An increase of cooling time seemed to decrease warpage and with a decrease of injection temperature should decrease warpage as well. In the case of conventional optimization, mold material was the factor with more contribution to warpage. Comparing the three designs, conventional straight-drilled channels design had the best results to improve warpage with an improvement up to 14%.

Country
Portugal
Related Organizations
Keywords

Arrefecimento convencional, Injection molding process, Conventional cooling, Otimização do processo, Processo de moldação por injeção, Otimização do arrefecimento, Cooling optimization, Conformal cooling, Arrefecimento conformal, Process optimization

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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!
0
Average
Average
Average
Green