The Experts below are selected from a list of 156 Experts worldwide ranked by ideXlab platform
K. M. Au - One of the best experts on this subject based on the ideXlab platform.
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Variable Distance Adjustment for Conformal Cooling Channel Design in Rapid Tool
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2014Co-Authors: K. M. Au, Kai Min YuAbstract:During thermoplastic injection moulding process, the gradual increase of the coolant temperature along the Conformal Cooling Channel (CCC) inside the rapid tool reduces the rate of heat transfer from the polymeric melt to the Cooling Channel surface at the outlet portion. Injection moulded defects such as irregular warpage of the part between the coolant inlet and outlet cannot be avoided. Rapid tooling (RT) technology offers a speedy and automatic method for rapid tool design and fabrication integrated with complex internal structure such as CCC. This paper presents a novel adjustment method for Cooling distance modification between the CCC and its mould cavity (or core) surface along the Cooling Channel. The proposed method can compensate the gradual increase of the coolant temperature from the coolant inlet to the coolant outlet. More heat can be transferred from the mould surface near the coolant outlet to the proposed variable distance Conformal Cooling Channel (VDCCC). In this study, the Cooling Channel distance modification relies on two adjustment attributes: (1) the adjustment direction and (2) the adjustment amount, between the mould cavity (or core) surface (terrain) and the Cooling Channel axis (polyline) after the linearized approximation. A computer-aided melt flow analysis tool of moldflow plastics insight is employed in the case study in order to demonstrate the feasibility of the proposed method. The Cooling performance of the proposed VDCCC design can be verified.
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Conformal Cooling Channel design and cae simulation for rapid blow mould
The International Journal of Advanced Manufacturing Technology, 2013Co-Authors: K. M. Au, Kai Min YuAbstract:Blow moulding is one of the most important polymer processing technologies to produce hollow-shaped parts at a short time. The Cooling stage takes up approximately two thirds of the complete blow moulding cycle. It becomes the major factor to determine the productivity and the quality of the blow-moulded part. The Cooling time and the quality part are controlled by an adequate Cooling Channel design inside the blow mould. Inappropriate Cooling Channel design will increase the Cooling time after part ejection. Recently, the success of integrating Conformal Cooling Channel (CCC) design in the injection moulding process has been proven by different research publications and practices. The merit of the applications of CCC can also be extended to the existing blow moulding process. In this study, an effective design method is proposed for integrating CCC into the blow mould with the aid of computer-aided design and analysis tools. The fabrication of integrating CCC into the blow mould by rapid tooling technology is explored. Computer-aided engineering simulation is employed to verify the Cooling performance of the CCC corresponding to the blow mould surface geometry. The analysed results are compared with those using the traditional straight line-drilled Cooling Channel (SLDCC) used in the blow moulding process. The results indicated that the Cooling time and temperature uniformity of the blow-moulded part can be effectively improved. The proposed CCC design has a shorter Cooling time and a lower part temperature than the SLDCC one.
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Visibility-based Conformal Cooling Channel generation for rapid tooling
Computer-aided Design, 2011Co-Authors: K. M. Au, Kai-ming Yu, W. K. ChiuAbstract:In plastic injection moulding process, Cooling Channel design is an essential factor that affects the quality of the moulded parts and the productivity of the process. Non-uniform Cooling or long Cooling cycle time would result if a poorly designed Cooling Channel is adopted. Due to limitations of traditional machining processes, the Cooling Channel is usually formed from straight-line drilled holes and only simple shapes are allowed, regardless of the shape complexity of the part being moulded. With the advent of rapid tooling technology, Cooling Channels in complex shapes can now be possible. However, there are not many design methodologies for supporting this type of Cooling Channel. In this paper, a methodology called visibility-based Cooling Channel generation is proposed for automatic preliminary Cooling Channel design for rapid tooling. The Cooling process between a mould surface and a Cooling Channel is considered analogous to whether they can be visible from each other. Without loss of generality, the mould surface is approximated by a polyhedral terrain and is normally offset. A number of point light sources together that can illuminate the whole polyhedral terrain are assigned to suitable terrain offset vertices. A Cooling Channel is then generated by connecting all the assigned light sources. When comparing the conventional verification and redesign methods by melt flow analysis, computer-aided design and, a better design of Cooling Channel for its mould surface results in a short time independent of the experience of mould engineer.
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Visibility-based Conformal Cooling Channel generation for rapid tooling
CAD Computer Aided Design, 2011Co-Authors: K. M. Au, Kai Min Yu, W. K. ChiuAbstract:In plastic injection moulding process, Cooling Channel design is an essential factor that affects the quality of the moulded parts and the productivity of the process. Non-uniform Cooling or long Cooling cycle time would result if a poorly designed Cooling Channel is adopted. Due to limitations of traditional machining processes, the Cooling Channel is usually formed from straight-line drilled holes and only simple shapes are allowed, regardless of the shape complexity of the part being moulded. With the advent of rapid tooling technology, Cooling Channels in complex shapes can now be possible. However, there are not many design methodologies for supporting this type of Cooling Channel. In this paper, a methodology called visibility-based Cooling Channel generation is proposed for automatic preliminary Cooling Channel design for rapid tooling. The Cooling process between a mould surface and a Cooling Channel is considered analogous to whether they can be visible from each other. Without loss of generality, the mould surface is approximated by a polyhedral terrain and is normally offset. A number of point light sources together that can illuminate the whole polyhedral terrain are assigned to suitable terrain offset vertices. A Cooling Channel is then generated by connecting all the assigned light sources. When comparing the conventional verification and redesign methods by melt flow analysis, computer-aided design and, a better design of Cooling Channel for its mould surface results in a short time independent of the experience of mould engineer. © 2010 Elsevier B.V. All rights reserved.
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A scaffolding architecture for Conformal Cooling design in rapid plastic injection moulding
The International Journal of Advanced Manufacturing Technology, 2007Co-Authors: K. M. AuAbstract:Cooling design of plastic injection mould is important because it not only affects part quality but also the injection moulding cycle time. Traditional injection mould Cooling layout is based on a conventional machining process. As the conventional drilling method limits the geometric complexity of the Cooling layout, the mobility of Cooling fluid within the injection mould is confined. Advanced rapid tooling technologies based on solid freeform fabrications have been exploited to provide a time-effective solution for low-volume production. In addition, research has made attempts to incorporate Conformal Cooling Channel in different rapid tooling technologies. However, the Cooling performance does not meet the mould engineer’s expectations. This paper proposes a novel scaffold Cooling for the design of a more Conformal and hence more uniform Cooling Channel. CAD model for constructing the scaffolding structure is examined and Cooling performances are validated by computer-aided engineering (CAE) and computer fluid dynamics (CFD) analysis.
S H Masood - One of the best experts on this subject based on the ideXlab platform.
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Optimum Cooling Channels Design and Thermal Analysis of an Injection Moulded Plastic Part Mould
Materials Science Forum, 2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:Cooling Channel design is important in mould designs to achieve shorter cycles, dimensional stability and reduced part stresses. Traditionally, Cooling Channels have been machined into mould components to avoid interference with the ejection system, coring, cavity and other mould details. Over the years straight drilled Cooling Channels have given away, in part, to Conformal Cooling technique often using free form fabrication techniques. This paper presents a study of optimised mould design with Conformal Cooling Channel using finite element analysis. Various configurations of Conformal Cooling Channels have been developed. The part Cooling time using the Conformal Cooling Channels and the straight Cooling Channels in the mould are computed using the Pro/Mechanica Thermal FEA software. Results are presented based on temperature distribution and Cooling time using steady state and transient analysis conditions. The results show a reduction in cycle time for the plastic part with Conformal Cooling Channel design.
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Thermal analysis of Conformal Cooling Channels in injection moulding
2020Co-Authors: S H Masood, Nguyen Nam TrangAbstract:Cooling Channel system in injection mould is crucial because it affects the moulded part quality and the rate of the moulding process. This paper presents a study of novel Conformal Cooling Channel designs for injection moulds. Various Cooling Channel designs including conventional and Conformal types are developed and analysed using Pro/Mechanica Thermal simulation software. Various designs and configurations including variation in Channel cross section geometry are compared and evaluated in terms of Cooling efficiency based on temperature distribution and Cooling time using steady state and transient analysis conditions. Results show that the Conformal Cooling Channel system with novel cross section designs obtain shorter Cooling time and better temperature distribution in comparison to the conventional Cooling Channels.
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Finite Element Thermal Analysis of Conformal Cooling Channels in Injection Moulding
2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:The process cycle time in injection moulding process depends greatly on the Cooling time of the plastic part, which is facilitated by the Cooling Channels in the injection mould. Effective Cooling Channel design in the mould is important because it not only affects cycle time but also the part quality. Traditional Cooling Channels are normally made of straight drilled holes in the mould, which have limitations in geometric complexity as well as Cooling fluid mobility within the injection mould. Over the years, Conformal Cooling techniques are being introduced as effective alternative to conventional Cooling. The main objective of this study is to determine an optimum design for Conformal Cooling Channel of an injection moulded plastic part using finite element analysis and thermal heat transfer analysis. The part Cooling time is optimised by Conformal Cooling Channels in the mould using the ANSYS thermal analysis software. Analysis of virtual models showed that those with Conformal Cooling Channels predicted a significant reduction of cycle time with expected improvement in part quality.
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CYCLE TIME REDUCTION IN INJECTION MOULDING WITH Conformal Cooling ChannelS
2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:Cooling Channel design in injection moulding is very important as it greatly affects the cycle time. Traditionally, Cooling Channels have been machined into mould components with gun-barrel drilling, with that only straight Channels were possible to manufacture. An advanced method of Cooling system that ‘conforms’ to the shape of the part in the core, cavity and strippers can be made possible with free form fabrication or 3D printing. This paper presents a study on optimized mould design of Conformal Cooling Channel for a plastic part. Core and cavities have been designed using Pro/Molddesign and circular configurations of Conformal Cooling Channels have been developed with Pro-Engineer software. The part Cooling time has been optimized by using these Conformal Cooling Channels and compared with straight Channels in the mould using ANSYS thermal simulation software. Results are presented based on temperature distribution and Cooling time using transient thermal analysis conditions. The results provide a reduction in cycle time for the plastic part, which will lead increase of production volume.
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an investigation on fabrication of Conformal Cooling Channel with direct metal deposition for injection moulding
2014Co-Authors: Abul B M Saifullah, S H Masood, Mostafa Nikzad, M BrandtAbstract:Rapid tooling (RT) and rapid manufacturing (RM) technologies have demonstrated the potential to manufacture injection molds with Cooling Channels, which are Conformal to the molding cavity. This article presents a study involving fabrication of square cross sectional Conformal Cooling Channel (SCSCCC) using laser based rapid manufacturing process of Direct Metal Deposition (DMD). The DMD process can be used for fabrication of Conformal Cooling Channels of different cross section and of different configuration. For optimization of the best cross sectional Conformal Cooling Channel, five different types of cross sectional shapes of Conformal Cooling Channels have been designed and analyzed for an industrial plastic part cavity mold. Optimization has been done through transient thermal Finite Element Analysis (FEA) for best temperature distribution in the cavity mold by ANSYS Workbench simulation software. Finally, the mold has been fabricated with square cross sectional Conformal Cooling Channel by the DMD and tested by injection molding of a sample plastic part and compared with conventional straight Cooling Channel (CSCC) mold. Simulation and experimental results show that SCSCCC shows better temperature distribution in the mold which reduces cycle time of the injection molding process.
Shuji Aiba - One of the best experts on this subject based on the ideXlab platform.
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Numerical and experimental investigation of process parameters optimization in plastic injection molding using multi-criteria decision making
Simulation Modelling Practice and Theory, 2018Co-Authors: Satoshi Kitayama, Masahiro Takano, Yusuke Yamazaki, Shuji AibaAbstract:Abstract In plastic injection molding (PIM), the process parameters such as packing pressure, melt temperature, and Cooling time should be adjusted and optimized for high product quality and high productivity. Warpage is one of the major defects in the PIM and should be minimized for high quality. Cycle time should be minimized for the high productivity. In addition to the warpage and the cycle time, clamping force affects the product both the quality and the productivity. Therefore, for the high product quality and the high productivity, it is important to minimize the warpage, the cycle time and the clamping force simultaneously. In this paper, a multi-objective optimization of process parameters in PIM for minimizing three objectives is performed. Numerical simulation in the PIM is generally so intensive that a sequential approximate optimization using radial basis function network is adopted to determine the optimal process parameters. The radar chart is used to perform the trade-off analysis among three objective functions. In addition, the better and worse solution are newly introduced for the trade-off analysis. It is found through the trade-off analysis that all objective functions of the Conformal Cooling Channel are well improved in comparison with the ones of the conventional Cooling Channel. Therefore, 43% warpage reduction, 1,7% clamping force reduction, and 47% cycle time reduction can successfully be achieved using the Conformal Cooling Channel. Based on the numerical result, the experiment using PIM machine (GL30-LP, Sodick) is carried out. The Conformal Cooling Channel is developed by the metal 3D printer (OPM250L, Sodick). Through the numerical and experimental result, the validity of the proposed approach is examined.
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numerical optimization of process parameters in plastic injection molding for minimizing weldlines and clamping force using Conformal Cooling Channel
Journal of Manufacturing Processes, 2018Co-Authors: Satoshi Kitayama, Masahiro Takano, Kanako Tamada, Shuji AibaAbstract:Abstract Weldlines are one of the major defects in plastic injection molding (PIM). Since the weldlines have an influence on not only the appearance of product but also the strength, it is important to reduce the weldlines as much as possible. The melt plastic will be quickly solidified with the low weldline temperature, which results in long weldlines. The weldline temperature is one of the important factors for the weldlines reduction. Clamping force also affect the product quality, but the relationship between the weldlines and the clamping force is rarely discussed in the literature. In this paper, the minimum weldline temperature is maximized for the weldlines reduction, whereas the clamping force is minimized for the high product quality. Therefore, a multi-objective design optimization is performed and the pareto-frontier between them is identified. Numerical simulation in PIM is generally so intensive that a sequential approximate optimization (SAO) using a radial basis function (RBF) network is used to identify the pareto-frontier. Through the numerical simulation, the trade-off between the minimum weldline temperature and the clamping force is clarified.
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Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using Conformal Cooling Channel
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Satoshi Kitayama, Hiroyasu Miyakawa, Masahiro Takano, Shuji AibaAbstract:In this paper, Cooling performance of Conformal Cooling Channel in plastic injection molding (PIM) is numerically and experimentally examined. To examine the Cooling performance, cycle time and warpage are considered. Melt temperature, injection time, packing pressure, packing time, Cooling time, and Cooling temperature are taken as the design variables. A multi-objective optimization of the process parameters is then performed. First, the process parameters of Conformal Cooling Channel are optimized. Numerical simulation in the PIM is so intensive that a sequential approximate optimization using a radial basis function network is used to identify a pareto-frontier. It is found from the numerical result that the Cooling performance of Conformal Cooling Channel is much improved, compared to the conventional Cooling Channel. Based on the numerical result, the Conformal Cooling Channel is developed by using additive manufacturing technology. The experiment is then carried out to examine the validity of the Conformal Cooling Channel. Through numerical and experimental result, it is confirmed that the Conformal Cooling Channel is effective to the short cycle time and the warpage reduction.
Abul B M Saifullah - One of the best experts on this subject based on the ideXlab platform.
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Finite Element Thermal Analysis of Conformal Cooling Channels in Injection Moulding
2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:The process cycle time in injection moulding process depends greatly on the Cooling time of the plastic part, which is facilitated by the Cooling Channels in the injection mould. Effective Cooling Channel design in the mould is important because it not only affects cycle time but also the part quality. Traditional Cooling Channels are normally made of straight drilled holes in the mould, which have limitations in geometric complexity as well as Cooling fluid mobility within the injection mould. Over the years, Conformal Cooling techniques are being introduced as effective alternative to conventional Cooling. The main objective of this study is to determine an optimum design for Conformal Cooling Channel of an injection moulded plastic part using finite element analysis and thermal heat transfer analysis. The part Cooling time is optimised by Conformal Cooling Channels in the mould using the ANSYS thermal analysis software. Analysis of virtual models showed that those with Conformal Cooling Channels predicted a significant reduction of cycle time with expected improvement in part quality.
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Optimum Cooling Channels Design and Thermal Analysis of an Injection Moulded Plastic Part Mould
Materials Science Forum, 2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:Cooling Channel design is important in mould designs to achieve shorter cycles, dimensional stability and reduced part stresses. Traditionally, Cooling Channels have been machined into mould components to avoid interference with the ejection system, coring, cavity and other mould details. Over the years straight drilled Cooling Channels have given away, in part, to Conformal Cooling technique often using free form fabrication techniques. This paper presents a study of optimised mould design with Conformal Cooling Channel using finite element analysis. Various configurations of Conformal Cooling Channels have been developed. The part Cooling time using the Conformal Cooling Channels and the straight Cooling Channels in the mould are computed using the Pro/Mechanica Thermal FEA software. Results are presented based on temperature distribution and Cooling time using steady state and transient analysis conditions. The results show a reduction in cycle time for the plastic part with Conformal Cooling Channel design.
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CYCLE TIME REDUCTION IN INJECTION MOULDING WITH Conformal Cooling ChannelS
2020Co-Authors: Abul B M Saifullah, S H MasoodAbstract:Cooling Channel design in injection moulding is very important as it greatly affects the cycle time. Traditionally, Cooling Channels have been machined into mould components with gun-barrel drilling, with that only straight Channels were possible to manufacture. An advanced method of Cooling system that ‘conforms’ to the shape of the part in the core, cavity and strippers can be made possible with free form fabrication or 3D printing. This paper presents a study on optimized mould design of Conformal Cooling Channel for a plastic part. Core and cavities have been designed using Pro/Molddesign and circular configurations of Conformal Cooling Channels have been developed with Pro-Engineer software. The part Cooling time has been optimized by using these Conformal Cooling Channels and compared with straight Channels in the mould using ANSYS thermal simulation software. Results are presented based on temperature distribution and Cooling time using transient thermal analysis conditions. The results provide a reduction in cycle time for the plastic part, which will lead increase of production volume.
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an investigation on fabrication of Conformal Cooling Channel with direct metal deposition for injection moulding
2014Co-Authors: Abul B M Saifullah, S H Masood, Mostafa Nikzad, M BrandtAbstract:Rapid tooling (RT) and rapid manufacturing (RM) technologies have demonstrated the potential to manufacture injection molds with Cooling Channels, which are Conformal to the molding cavity. This article presents a study involving fabrication of square cross sectional Conformal Cooling Channel (SCSCCC) using laser based rapid manufacturing process of Direct Metal Deposition (DMD). The DMD process can be used for fabrication of Conformal Cooling Channels of different cross section and of different configuration. For optimization of the best cross sectional Conformal Cooling Channel, five different types of cross sectional shapes of Conformal Cooling Channels have been designed and analyzed for an industrial plastic part cavity mold. Optimization has been done through transient thermal Finite Element Analysis (FEA) for best temperature distribution in the cavity mold by ANSYS Workbench simulation software. Finally, the mold has been fabricated with square cross sectional Conformal Cooling Channel by the DMD and tested by injection molding of a sample plastic part and compared with conventional straight Cooling Channel (CSCC) mold. Simulation and experimental results show that SCSCCC shows better temperature distribution in the mold which reduces cycle time of the injection molding process.
Kai Min Yu - One of the best experts on this subject based on the ideXlab platform.
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Variable Distance Adjustment for Conformal Cooling Channel Design in Rapid Tool
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2014Co-Authors: K. M. Au, Kai Min YuAbstract:During thermoplastic injection moulding process, the gradual increase of the coolant temperature along the Conformal Cooling Channel (CCC) inside the rapid tool reduces the rate of heat transfer from the polymeric melt to the Cooling Channel surface at the outlet portion. Injection moulded defects such as irregular warpage of the part between the coolant inlet and outlet cannot be avoided. Rapid tooling (RT) technology offers a speedy and automatic method for rapid tool design and fabrication integrated with complex internal structure such as CCC. This paper presents a novel adjustment method for Cooling distance modification between the CCC and its mould cavity (or core) surface along the Cooling Channel. The proposed method can compensate the gradual increase of the coolant temperature from the coolant inlet to the coolant outlet. More heat can be transferred from the mould surface near the coolant outlet to the proposed variable distance Conformal Cooling Channel (VDCCC). In this study, the Cooling Channel distance modification relies on two adjustment attributes: (1) the adjustment direction and (2) the adjustment amount, between the mould cavity (or core) surface (terrain) and the Cooling Channel axis (polyline) after the linearized approximation. A computer-aided melt flow analysis tool of moldflow plastics insight is employed in the case study in order to demonstrate the feasibility of the proposed method. The Cooling performance of the proposed VDCCC design can be verified.
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Conformal Cooling Channel design and cae simulation for rapid blow mould
The International Journal of Advanced Manufacturing Technology, 2013Co-Authors: K. M. Au, Kai Min YuAbstract:Blow moulding is one of the most important polymer processing technologies to produce hollow-shaped parts at a short time. The Cooling stage takes up approximately two thirds of the complete blow moulding cycle. It becomes the major factor to determine the productivity and the quality of the blow-moulded part. The Cooling time and the quality part are controlled by an adequate Cooling Channel design inside the blow mould. Inappropriate Cooling Channel design will increase the Cooling time after part ejection. Recently, the success of integrating Conformal Cooling Channel (CCC) design in the injection moulding process has been proven by different research publications and practices. The merit of the applications of CCC can also be extended to the existing blow moulding process. In this study, an effective design method is proposed for integrating CCC into the blow mould with the aid of computer-aided design and analysis tools. The fabrication of integrating CCC into the blow mould by rapid tooling technology is explored. Computer-aided engineering simulation is employed to verify the Cooling performance of the CCC corresponding to the blow mould surface geometry. The analysed results are compared with those using the traditional straight line-drilled Cooling Channel (SLDCC) used in the blow moulding process. The results indicated that the Cooling time and temperature uniformity of the blow-moulded part can be effectively improved. The proposed CCC design has a shorter Cooling time and a lower part temperature than the SLDCC one.
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Visibility-based Conformal Cooling Channel generation for rapid tooling
CAD Computer Aided Design, 2011Co-Authors: K. M. Au, Kai Min Yu, W. K. ChiuAbstract:In plastic injection moulding process, Cooling Channel design is an essential factor that affects the quality of the moulded parts and the productivity of the process. Non-uniform Cooling or long Cooling cycle time would result if a poorly designed Cooling Channel is adopted. Due to limitations of traditional machining processes, the Cooling Channel is usually formed from straight-line drilled holes and only simple shapes are allowed, regardless of the shape complexity of the part being moulded. With the advent of rapid tooling technology, Cooling Channels in complex shapes can now be possible. However, there are not many design methodologies for supporting this type of Cooling Channel. In this paper, a methodology called visibility-based Cooling Channel generation is proposed for automatic preliminary Cooling Channel design for rapid tooling. The Cooling process between a mould surface and a Cooling Channel is considered analogous to whether they can be visible from each other. Without loss of generality, the mould surface is approximated by a polyhedral terrain and is normally offset. A number of point light sources together that can illuminate the whole polyhedral terrain are assigned to suitable terrain offset vertices. A Cooling Channel is then generated by connecting all the assigned light sources. When comparing the conventional verification and redesign methods by melt flow analysis, computer-aided design and, a better design of Cooling Channel for its mould surface results in a short time independent of the experience of mould engineer. © 2010 Elsevier B.V. All rights reserved.
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variable radius Conformal Cooling Channel for rapid tool
Materials Science Forum, 2006Co-Authors: K. M. Au, Kai Min YuAbstract:The Cooling system of a plastic injection mould is important as it affects the quality and productivity of the polymeric components or assemblies. Contemporary Cooling Channel design is confined to simple configurations of straight-drilled coolant passageway around the mould insert. Undesirable defects resulted during injection moulding, such as warpage, are inevitable. The application of rapid tool (RT) based on solid freeform fabrication (SFF) technologies with Conformal Cooling Channel (CCC) design has provided a profound opportunity in quality improvement of polymeric components. In this study, a novel design of variable radius Conformal Cooling Channel (VRCCC) is proposed to achieve better uniform Cooling performance. Thermal-FEA and melt flow analysis are used to validate the method.