Production of Plastic Injection Molds with Conformal Cooling Channels by Laminated Brazing Method

Year 2020, , 780 - 789, 01.09.2020

Mustafa Göktaş , Abdulmecit Güldaş

https://doi.org/10.35378/gujs.621930

Cited By: 5

Abstract

In this study, an experimental research
has been carried out for the production of plastic injection molds with
conformal cooling channels by laminated brazing. In order to increase the
efficiency of the cooling system, conformal cooling channels are designed. Mold
cores and cavities were cut into layers and machined into plates. The plates
are combined with vacuum brazing method to produce plastic injection mold with conformal
cooling channels. The production of plastic parts was tried with two molds with
conformal and straight cooling channels. According to the results, both the
cycle time and the preparation time of the plastic injection mold for
production were shortened by the use of conformal cooling channels.

Keywords

Conformal cooling channels, Plastic injection molding, Enhanced cooling system, Vacuum brazing, Laminated tooling

Supporting Institution

Gazi University Projects of Scientific Investigation (BAP)

Project Number

Project Number: 07/2018-08

Thanks

We would like to thank Gazi University Projects of Scientific Investigation (BAP) for their support.

References

• 1) Dimla, D. E., M. Camilotto, and F. Miani. "Design and optimisation of conformal cooling channels in injection moulding tools." Journal of Materials Processing Technology 164 (2005): 1294-1300.
• 2) Yadegari, Mahdi, Hamed Masoumi, and Mohsen Gheisari. "Optimization of Cooling Channels in Plastic Injection Molding." International Journal of Applied Engineering Research 11.8 (2016): 5777-5780.
• 3) Qiao, H. "A systematic computer-aided approach to cooling system optimal design in plastic injection molding." International journal of mechanical sciences 48.4 (2006): 430-439.
• 4) Wang, Gui-long, Guo-qun Zhao, and Xiao-xin Wang. "Heating/cooling channels design for an automotive interior part and its evaluation in rapid heat cycle molding." Materials & Design 59 (2014): 310-322.
• 5) Li, C. G., Li, C. L., Liu, Y., & Huang, Y. (2012). A new C-space method to automate the layout design of injection mould cooling system. Computer-Aided Design, 44(9), 811-823.
• 6) Kovács, J. G., and B. Sikló. "Investigation of cooling effect at corners in injection molding." International Communications in Heat and Mass Transfer 38.10 (2011): 1330-1334.
• 7) Altaf, Khurram, V. R. Raghavan, and A. M. A. Rani. "Comparative thermal analysis of circular and profiled cooling channels for injection mold tools." Journal of Applied Sciences 11.11 (2011): 2068-2071.
• 8) Hassan, H., Regnier, N., Lebot, C., Pujos, C., & Defaye, G. (2009). Effect of cooling system on the polymer temperature and solidification during injection molding. Applied Thermal Engineering, 29(8-9), 1786-1791.
• 9) Zhou, Huamin, and Dequn Li. "Mold cooling simulation of the pressing process in TV panel production." Simulation Modelling Practice and Theory 13.3 (2005): 273-285.
• 10) Saifullah, A. B. M., S. H. Masood, and Igor Sbarski. "New cooling channel design for injection moulding." Proceedings of the World Congress on Engineering. Vol. 1. 2009.
• 11) Khan, Muhammad, et al. "Cycle time reduction in injection molding process by selection of robust cooling channel design." ISRN Mechanical Engineering 2014 (2014).
• 12) Kitayama, Satoshi, et al. "Numerical and experimental investigation on process parameters optimization in plastic injection molding for weldlines reduction and clamping force minimization." The International Journal of Advanced Manufacturing Technology 97.5-8 (2018): 2087-2098.
• 13) Lu, Chun-Ting, Chun-Hsein Chen, and Shi-Chang Tseng. "Application of conformal cooling to reduce cooling time and warpage of a U-shaped plate." AIP Conference Proceedings. Vol. 2065. No. 1. AIP Publishing, 2019.
• 14) M.S. Shinde, K.M. Ashtankar, Additive manufacturing-assisted conformal coolingchannels in mold manufacturing processes, Adv. Mech. Eng. 9 (5) (2017).
• 15) Asberg, M., et al. "Influence of post treatment on microstructure, porosity and mechanical properties of additive manufactured H13 tool steel." Materials Science and Engineering: A 742 (2019): 584-589.
• 16) Jahan, Suchana A., et al. "Thermo-mechanical design optimization of conformal cooling channels using design of experiments approach." Procedia Manufacturing 10 (2017): 898-911.
• 17) Rahim, Shayfull Zamree Abd, et al. "Improving the quality and productivity of molded parts with a new design of conformal cooling channels for the injection molding process." Advances in polymer technology 35.1 (2016).
• 18) Dang, Xuan-Phuong, and Hong-Seok Park. "Design of U-shape milled groove conformal cooling channels for plastic injection mold." International Journal of precision engineering and manufacturing 12.1 (2011): 73-84.
• 19) Ferreira, J. C., and A. Mateus. "Studies of rapid soft tooling with conformal cooling channels for plastic injection moulding." Journal of Materials Processing Technology 142.2 (2003): 508-516.
• 20) Sun, Y. F., K. S. Lee, and A. Y. C. Nee. "Design and FEM analysis of the milled groove insert method for cooling of plastic injection moulds." The International Journal of Advanced Manufacturing Technology 24.9-10 (2004): 715-726.
• 21) Ahari, Hossein, Amir Khajepour, and Sanjeev Bedi. "Laminated Injection Mould with Conformal Cooling Channels: Optimization, Fabrication and Testing." (2013).
• 22) Eiamsa-Ard, Kunnayut, and Kittinat Wannissorn. "Conformal bubbler cooling for molds by metal deposition process." Computer-Aided Design 69 (2015): 126-133.
• 23) Mustafa Göktaş, Abdulmecit Güldaş, Ömer Bayraktar, “Cooling of Plastic Injection Moulds Using Design Adaptive Cooling Canals”, International Conference on Engineering and Natural Science (ICENS 2016), 24-28 May 2016, Sarajevo
• 24) Abdulmecit Güldaş, Mustafa Göktaş, “Comparson of Straight, Spiral Conformal and Zig-zag Conformal Cooling Channels in Plastic Injection Molds”, International Symposium on Innovative Approaches in Scientific Studies (ISAS 2019), April 19-21,2019, Ankara, Turkey
• 25) Bryden, B. G., and I. R. Pashby. "Hot platen brazing to produce laminated steel tooling." Journal of Materials Processing Technology 110.2 (2001): 206-210.
• 26) Esmati, K., et al. "Study on the microstructure and mechanical properties of diffusion brazing joint of C17200 Copper Beryllium alloy." Materials & Design 53 (2014): 766-773.
• 27) Bryden, B. G., et al. "Laminated steel tooling in the aerospace industry." Materials & Design 21.4 (2000): 403-408.
• 28) Yoo, Seungryeol, and Daniel F. Walczyk. "A preliminary study of sealing and heat transfer performance of conformal channels and cooling fins in laminated tooling." Journal of manufacturing science and engineering 129.2 (2007): 388-399.
• 29) Park, S. J., and T. H. Kwon. "Optimal cooling system design for the injection molding process." Polymer Engineering & Science 38.9 (1998): 1450-1462.
• 30) Jahan, Suchana A., and Hazim El-Mounayri. "Optimal conformal cooling channels in 3D printed dies for plastic injection molding." Procedia Manufacturing 5 (2016): 888-900.