ME 617 Rapid Product Development Report

7/24/2019 ME 617 Rapid Product Development Report

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INDIAN INSTITUTE OF

TECHNOLOGY BOMBAY

Course Seminar Report

ME 617

Conformal Cooling

Arun Sharma 153101013

Unmesh Pawale 153100069


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Abstract


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IntroductionWhile designing molds, effective cooling sstem design !las crucial role"

#ooling is ver im!ortant in as!ects of mold and the !art for long tool life, less ccletime and less distortion" $n%ection molding molds hot in%ected !lastic in desired sha!e"

&he !lastic !art must 'e cooled to the tem!erature !oint where it can withstand the action

of the e%ectors and its sha!e is maintained after e%ection" &his !rocess can !roduce wide

variet (highl com!le) geometries* of !roducts and in large +uantit in !lastic material"

&herefore designing a !ro!er mold have higher im!ortance" esides, the design of a

mold-cooling sstem re+uires a num'er of considerations, such as the com!osition of the

coolant, !ressure dro! of the coolant, and runner sstem" Among them, we focus on the

as!ect of the three-dimensional (3.* sha!es of the cooling channels, which should 'e

conformal to the given !lastic !art"

&ools with conformal cooling channels, which are fa'ricated ' 3. !rinting,

(generall ' Direct Metal Laser Sintering* have demonstrated im!rovements in 'oth

the !roduction rate and the !art +ualit as com!ared with conventional !roduction tools"

Sachs et al" e)amined their conformal cooling tools in industrial a!!lications/ the reduce

the ccle time ' 15 and the !art distortion ' 9" &he high efficienc of a conformal

channel in thermal control is useful not onl for cooling !ur!oses, 'ut also for mold

heating"

ig" .2S and design with conformal cooling channel


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As in%ection molding !rocess grows ra!idl in industries, the are discovering advantages

of conformal cooling in maintaining tem!erature, reduction in hots!ot region,maintaining tem!erature uniformit along the flow" esides that it reduction in ccle

time, higher !roduction rate, im!roved !lastic !art +ualit"

4ven so, man manufacturers, some of them with long e)!erience in the industr,

still thin conformal cooling is too difficult and too e)!ensive" &he thin these things

'ecause 'oth used to 'e true"


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Conformal cooling channels (CCC)

#onformal #ooling channels are channels design 'ased on !roduct contour" $nconventional cooling we generall does not consider geometr 'ut it will 'e ineffective in

com!le) geometries, so ### are the 'est solution for com!le) geometries"

&he method to !roduce mold with ### is .2S" ecause conventional drilling

methods gets o'solete as com!le)it increases" .2S is an additive manufacturing

technolog that !roduces !arts from 3. #A. models ' melting metal !owder with a

focused laser 'eam, laer ' laer, in strata as thin as 0 7m" &he first .2S material

availa'le to mold maers was a 'ron8e allo ideal for molds and inserts used in low- and

medium-volume !roduction runs"

.2S not onl does eliminate the need for secondar drilling, 'ut it also can 'e used to

mae o!timi8ed cooling channels that closel conform to the surface of the mold cavit,

or that reach crucial hot s!ots that conventional channels cant" $n addition, the channels

can 'e formed in sha!es that add to the volume of coolant flow or that generate

tur'ulence to carr off more heat:maing the channels far more efficient and mold

tem!eratures more uniform"

Some toolmaers does not acce!t conformal cooling 'ecause the thin the are

doing fine with conventional methods and maing re+uired !rofits without the use of newtechnologies" ut conformal cooling 'asicall doesnt change the 'asic !rocess" $t

stretches new design and increases !rocess efficienc to mae more !rofit in same

environment" ;ther a!!roach is Whats more, conformal cooling is a !roven technolog"

;ver the !ast few ears, 'enchmars of conformal cooling against traditional !rocesses

have documented significant reductions in two of the most im!ortant cost drivers of

in%ection molding< cooling times and scra! rates"


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Eects of Conformal Cooling

#ase Stud Water meter cover manufacturing ' in%ection molding !uts light on

conformal coolings 'enefits" &ool of this is !re!ared ' direct metal laser sintering .

1* #ooling Sstem

=eat &ransfer in $n%ection 2olding

=eat removed from cavit to mold 'ase to cooling channels

=eat removed from mold 'ase

2old surface radiation

2old surface convection

=eat removed at e%ection

2) Temperature distributions2aterial thermal Pro!erties for 2old and Part

Steel P! Pol"#ro#"lene $PP% ABS

Den&it" ('g/m() )*!! +!! ,!-

S#e/i0/ 1eat (2/('g 3 4)) -5! ,+!! ,+!

T1ermal /on67/ti8it" (9/(m 4)) + : :

Tmelt (;C) : ! (!

Te


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Conformal Cooling (Heating hase)

When molten !lastic comes in contact with mold it gets heated and cooling sstem starts

woring this is heating !hase in sstem" .uring heating in conventional cooling start

tem!erature difference is ver high, ecause of no !ro!er alignment of mold channel"

#ooling rate is nearl 8ero and then is starts increases as time increases" #ooling rate

never 'e constant in conventional cooling"

using conformal cooling die can 'e !revented from higher heat treatment

(generall in in%ection molding !lastic have tem!erature of 1100 degree #elsius *" .ie can

maintained at lower tem!erature and cooling rate" So as to reduce distortion in !art after

cooling"

igure shown in 'elow is result of e)!eriment of tem!erature distri'ution test and

it is taen from >?; >50 thermo- gra!hic camera" And two different !lots of twocooling sstems"

ig conformal cooling vs conventional cooling heating !hase


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Conformal Cooling (Cooling Phase)

After die !ressing there is some time to cool !art and also mold" &his time maes

crucial effect on !roduced !art" .uring cooling !hase constant cooling rate leads to less

distortion in final !roduct" &his advantage is given ' conformal cooling"

Fig. Conformal /ooling $Cooling P1a&e%


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Effect on Ccle Time

or the considered case (water meter coverings* general ccle time is 55sec" &ime for

o!ening, closing, !art e%ection and e%ection remains constant as conventional, 'ut CC

reduces !2"of ccle time as that of conventional cooling"

2ost of ccle time utili8ed in cooling of li+uid !hase !art" #ooling channels

maes im!act on cooling rates also it maes easier to !art e%ection results in reduction in

ccle time"

or !roduction of 100000 !arts it saves1@000 (#orth $%&'2 rupees )


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Effects on Cost

What cost 'enefits should ou e)!ect from using conformal coolingB &hat de!ends to

some degree on our !roduction levels" $n general, low-volume manufacturers get their

greatest savings from the reduced tooling costs of .2S" 2idrange volumes:sa, u! to

a million !arts:incur savings from shortened ccle times that increase !roductivit"

=igh-end !roducers of !lastic !arts (in the millions* also rea! the rewards of faster

cooling times, of course, 'ut at these +uantities, the elimination of scra! caused '

uneven tem!erature distri'ution 'ecomes an im!ortant source of savings as well"

amiliarit with conformal cooling leads to other 'enefits as well" #om!anies using

.2S are a'le to tae on molding %o's their com!etition cant touch" Production

standards for +ualit and waste elimination can 'e much higher" .esigners, freed from

cooling constraints and thining in terms of design-driven manufacturing rather than

manufacturing-driven design, are a'le to create free-form sha!es that would have

!reviousl 'een !rohi'itive for in%ection molding"

;f course, there are a great man other factors that will still affect !rocessing time and

+ualit" #lean, filtered coolant li+uid is alwas desira'le" Shorter cooling times wont

change our material insertion and !art e)traction times" And !lastic !art +ualit is

de!endent on a great man !eri!heral factors< heaters, s!rue and no88le diameters, and so

forth" ut if cooling times are creating a !roduction 'ottlenec, or uneven cooling is

affecting !art +ualit, o!timi8ed conformal cooling channels 'uilt with .2S can save

ou !lent"


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Results

&o !resent the eas use of techni+ue and the cooling !erformance of the channels

generated ' method, we demonstrate it on two e)am!le models with com!le) sha!e" As

illustrated in the following two case studies, method ields a glo'al design solution

without e)tra !ost-!rocessing, and all the conformal cooling channels are generated

automaticall"

&he simulations in tests are made using the in%ection molding simulation software

2oldlow $nsight" $n the stud, the melt of !olmer is assumed to have a uniform initial

tem!erature, namel the melt temperature that can 'e selected in the software for the

cooling calculation" &he e%ection tem!erature of the molding must also 'e s!ecified/ it

lies 'etween the melt and mold surface tem!eratures" Steel P@0 is used for the !art-

forming com!onents of the molds"

&he 'enefits of conformal cooling studied" 4ffects on tem!erature distri'ution,

ccle time, !roductivit, cost is ela'orated in this re!ort"


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*eferences

Pa#er on A7tomati/ 6e&ign of /onformal /ooling /ir/7it& for ra#i6tooling

Y7 9anga=>= 4ai?Min Y7a= C1arlie C.L. 9ang@= Y7n@o 1ang@a De#artment of In67&trial an6 S"&tem& Engineering= T1e Hong 4ong Pol"te/1ni/ Uni8er&it"= Hong 4ong@ De#artment of Me/1ani/al an6 A7tomation Engineering= T1e C1ine&e Uni8er&it" of Hong 4ong= Hong 4ong

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ME 617 Rapid Product Development Report

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