Advertisement

Development and application of a conformal cooling channel with easy removal and smooth surfaces

  • Chil-Chyuan KuoEmail author
  • Zheng-Yan You
  • Jun-Yi Wu
  • Jun-Lin Huang
ORIGINAL ARTICLE

Abstract

The cooling time in an injection molding process comprises about 60 to 80% of the entire molding cycle. Throughput and molded part quality can be improved by the mold with conformal cooling channels. Injection molds or dies with conformal cooling channels have been developed by rapid tooling technology. However, the manufacturing process for the injection mold with conformal cooling channels made of ABS polymers is not environmentally friendly. In addition, the fabrication process for a wax cooling channel with complex geometrical shapes is very time-consuming. It was found that the wax filament fabricated by the mold made by indirect tooling has better quality. A method for fabricating long wax filament using the butt joint method was developed. The optimal process parameters for making the long wax filament by the butt joint method are the butt angle of 30°, wax temperature of 82 °C, and injection pressure of 0.6 kgf/cm2. The optimal process parameters for the surface quality improvement of wax cooling channels are the hot water temperature of 85 °C and the immersion time of 10 s. Finally, the rapid tooling technology was used to make the injection mold with a smooth surface.

Keywords

Injection molding Mold Conformal cooling channels Indirect tooling Wax filament 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This study was financially supported by the Ministry of Science and Technology of Taiwan under contract nos. MOST 107-2221-E-131-018, MOST 106-2221-E-131-010, MOST 106-2221-E-131-011, and MOST 105-2221-E-131-012.

References

  1. 1.
    AlMangour B, Yang JM (2017) Understanding the deformation behavior of 17-4 precipitate hardenable stainless steel produced by direct metal laser sintering using micropillar compression and TEM. Int J Adv Manuf Technol 90(1–4):119–126CrossRefGoogle Scholar
  2. 2.
    Scharowsky T, Bauereib A, Korner C (2017) Influence of the hatching strategy on consolidation during selective electron beam melting of Ti-6Al-4V. Int J Adv Manuf Technol 92(5–8):2809–2818CrossRefGoogle Scholar
  3. 3.
    Liu Y, Yang Y, Wang D (2016) A study on the residual stress during selective laser melting (SLM) of metallic powder. Int J Adv Manuf Technol 87(1–4):647–656CrossRefGoogle Scholar
  4. 4.
    Leite JL, Salmoria GV, Paggi RA, Ahrens CH, Pouzada AS (2012) Microstructural characterization and mechanical properties of functionally graded PA12/HDPE parts by selective laser sintering. Int J Adv Manuf Technol 59(5–8):583–591CrossRefGoogle Scholar
  5. 5.
    Lin H, Luo H, Huang W, Zhang X, Yao G (2016) Diffusion bonding in fabrication of aluminum foam sandwich panels. J Mater Process Technol 230:35–41CrossRefGoogle Scholar
  6. 6.
    Gorunov AI, Kh A (2016) Gilmutdinov, Study of the effect of heat treatment on the structure and properties of the specimens obtained by the method of direct metal deposition. Int J Adv Manuf Technol 86(9–12):2567–2574CrossRefGoogle Scholar
  7. 7.
    Kitayama S, Tamada K, Takano M, Aibad S (2018) Numerical optimization of process parameters in plastic injection molding for minimizing weldlines and clamping force using conformal cooling channel. J Manuf Process 32:782–790CrossRefGoogle Scholar
  8. 8.
    Vojnova E (2016) The benefits of a conforming cooling systems the molds in injection moulding process. Procedia Eng 149:535–543CrossRefGoogle Scholar
  9. 9.
    Holker R, Tekkaya AE (2016) Advancements in the manufacturing of dies for hot aluminum extrusion with conformal cooling channels. Int J Adv Manuf Technol 83(5–8):1209–1220CrossRefGoogle Scholar
  10. 10.
    Lim WS, Choi HS, Ahn SY, Kim BM (2014) Cooling channel design of hot stamping tools for uniform high-strength components in hot stamping process. Int J Adv Manuf Technol 70(5–8):1189–1203CrossRefGoogle Scholar
  11. 11.
    Wang X, Li Z, Gu J, Ruan S, Shen C, Wang X (2016) Reducing service stress of the injection-molded polycarbonate window by optimizing mold construction and product structure. Int J Adv Manuf Technol 86(5–8):1691–1704CrossRefGoogle Scholar
  12. 12.
    Brooks H, Brigden K (2016) Design of conformal cooling layers with self-supporting lattices for additively manufactured tooling. Addit Manuf 11:16–22CrossRefGoogle Scholar
  13. 13.
    Kuo CC, Xu WC (2018) Effects of different cooling channels on the cooling efficiency in the wax injection molding process. Int J Adv Manuf Technol 98(1–4):887–895CrossRefGoogle Scholar
  14. 14.
    Kuo CC, Chen WH, Xu WC (2017) A cost-effective approach for rapid manufacturing wax injection molds with complex geometrical shapes of cooling channels. Int J Adv Manuf Technol 91(5–8):1689–1695CrossRefGoogle Scholar
  15. 15.
    Kuo CC, Chen WH, Zhang JW, Tsai DA, Cao YL (2017) A new method of manufacturing a rapid tooling with different cross-sectional cooling channels. Int J Adv Manuf Technol 92(9–12):3481–3487CrossRefGoogle Scholar
  16. 16.
    Thomas D (2016) Costs, benefits, and adoption of additive manufacturing: a supply chain perspective. Int J Adv Manuf Technol 85(5–8):1857–1876CrossRefGoogle Scholar
  17. 17.
    Qiu Y, Huang H, Xu X (2018) Effect of additive particles on the performance of ultraviolet-cured resin-bond grinding wheels fabricated using additive manufacturing technology. Int J Adv Manuf Technol 97(9–12):3873–3882CrossRefGoogle Scholar
  18. 18.
    Fayed EM, Elmesalamy AS, Sobih M, Elshaer Y (2018) Characterization of direct selective laser sintering of alumina. Int J Adv Manuf Technol 94(5–8):2333–2341CrossRefGoogle Scholar
  19. 19.
    Cheah CM, Chua CK, Lee CW, Lim ST, Eu KH, Lin LT (2002) Rapid sheet metal manufacturing. Part 2: direct rapid tooling. Int J Adv Manuf Technol 19(7):510–515CrossRefGoogle Scholar
  20. 20.
    Du ZH, Chua CK, Chua YS, Loh-Lee KG, Lim ST (2002) Rapid sheet metal manufacturing. Part 1: indirect rapid tooling. Int J Adv Manuf Technol 19(6):411–417CrossRefGoogle Scholar
  21. 21.
    Kitayama S, Miyakawa H, Takano M, Aiba S (2017) Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel. Int J Adv Manuf Technol 88(5–8):1735–1744CrossRefGoogle Scholar
  22. 22.
    Armillotta A, Baraggi R, Fasoli S (2014) SLM tooling for die casting with conformal cooling channels. Int J Adv Manuf Technol 71(1–4):573–583CrossRefGoogle Scholar
  23. 23.
    Li Z, Wang X, Gu J, Ruan S, Shen C, Lyu Y, Zhao Y (2018) Topology optimization for the design of conformal cooling system in thin-wall injection molding based on BEM. Int J Adv Manuf Technol 94(1–4):1041–1059CrossRefGoogle Scholar
  24. 24.
    Liu C, Cai Z, Dai Y, Huang N, Xu F, Lao C (2018) Experimental comparison of the flow rate and cooling performance of internal cooling channels fabricated via selective laser melting and conventional drilling process. Int J Adv Manuf Technol 96(5–8):2757–2767CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringMing Chi University of TechnologyNew Taipei CityTaiwan

Personalised recommendations