• Title/Summary/Keyword: Design of Cooling Channels

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A Study on the Design of Cooling Channels of Injection Mould to Manufacture a Flat Part with a Partly Thick Volume (부분적으로 후육부를 가지는 평판형 제품의 제작을 위한 사출성형 금형의 냉각채널 설계에 관한 연구)

  • Ahn, Dong-Gyu;Park, Min-Woo;Kim, Hyung-Soo
    • Journal of the Korean Society for Precision Engineering
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    • v.29 no.8
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    • pp.824-833
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    • 2012
  • The shrinkage and the warpage of the moulded part are influenced by the design of the product and injection mould. In a flat part with a partly thick volume, the warpage of the flat part is created from the difference of the shrinkage between thin and thick regions. The warpage of the flat part with a partly thick volume can be reduced by a proper design of the cooling system in the injection mould. The goal of this paper is to design properly cooling channels of injection mould to manufacture a flat part with a partly thick volume. The conformal cooling channel is adopted to improve cooling characteristics of a region with the thick volume. The linear cooling channels are assigned to the other region. The proper design of the conformal cooling channels is obtained from three-dimensional injection molding analysis for various design alternatives. The moulding characteristics of the designed mould with both conformal and linear cooling channels are compared to those of the mould with linear cooling channels from viewpoints of temperature, shrinkage and warpage of the moulded part using numerical analysis. Injection mould with both conformal and linear cooling channels for the flat part with a partially thick volume is fabricated. In addition, injection moulding experiments are performed using the fabricated mould. From the results of the injection moulding experiments, it has been shown that the designed mould can successfully fabricate the flat part with a partially thick volume.

Design of Conformal Cooling Channels for the Mould of a Plastic Drawer of a Refrigerator by Analysis of Three-Dimensional Injection Moulding (3 차원 사출성형 해석을 통한 냉장고 플라스틱 서랍 제작용 사출 성형 금형의 형상적응형 냉각수로 설계)

  • Ahn, Dong-Gyu;Park, Min-Woo;Park, Seung-Hwa;Kim, Hyung-Su
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.34 no.10
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    • pp.1487-1492
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    • 2010
  • The objective of this study is to design the conformal cooling channels for the mould of a plastic drawer of a refrigerator by analysis of three-dimensional injection molding. In order to obtain the desired design of the conformal cooling channels, the influence of the diameter and the position of the conformal cooling channels on the moulding characteristics and the product qualities were quantitatively examined. From the results of the examination, an optimal design of the conformal cooling channels, which ensures uniform cooling and minimum potential deformation of the molded drawers, was estimated. By comparing the designed mould and a conventional mould with linear cooling channels from the viewpoints of the product qualities as well as cooling and cycle times, it was shown that the mould with conformal cooling channels can simultaneously improve the productivity of the injection moulding process and the product qualities.

DESIGN OF PARALLEL COOLING CHANNELS IN A PLASTIC INJECTION MOLD (사출 금형의 병렬 냉각 채널 설계 방법)

  • Kim, H.S.;Jung, H.K.;Han, B.Y.;Kim, Y.M.;Park, H.K.
    • Journal of computational fluids engineering
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    • v.17 no.3
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    • pp.93-98
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    • 2012
  • The injection molding process is suitable for manufacturing complicated plastic products. As the customer request higher quality products increase, realization of the precise dimensional and shape controls is getting more important. For this purpose it is important to obtain uniform cooling procedure over the whole surface of the high temperature molded plastic. Failure to this may lead to different shrinkage speed, internal stresses and unwanted shape deformations. It is necessary to distribute coolant flow rates to the main channel and to the sub-channels properly to insure uniform cooling process when there are parallel cooling channels. In this study, three-dimensional turbulent flow simulations for representative parallel cooling channels were performed. To insure the intended flow rate to each sub-channels, various shape designs for the channel system were investigated. The results show that as the Reynolds number increases the effect of shape design is more profound. Through the proper flow distribution, uniform cooling effects would be expected.

PERFORMANCE EVALUATION OF COOLING CHANNELS IN A PLASTIC INJECTION MOLD MODEL (사출금형의 냉각채널 성능 평가)

  • Kim, H.S.;Han, B.Y.;Lee, I.C.;Kim, Y.M.;Park, H.K.
    • Journal of computational fluids engineering
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    • v.17 no.2
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    • pp.53-57
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    • 2012
  • Design of the cooling channels of a plastic injection mold affects the quality and the productivity of the injection processes. In the injection process, the melted resin with high temperature enters the mold cavity, and just after the cavity is filled the heat should be dissipated through the cooling channels simultaneously. The purpose of this study is to analyse the heat transfer phenomenon and to estimate the temperature distribution in the mold to evaluate the cooling effect of the channels. The injection mold is assumed to have cooling channels of circular cross section and each channel has the same coolant flow rate. and The cavity has a rectangular shape. The results show that as the cooling channels get closer to the cavity surface, the cooling efficiency increases as might easily be guessed. However, due to the final hot resin flow from the gate an intensive cooling is required in that region.

Heating and Cooling Channel Design of Cross-Shaped Die for Warm Forming of Magnesium Alloy Sheet (Mg 온간성형을 위한 십자형상 금형의 가열/냉각 채널 설계)

  • Choi, S.C.;Ko, D.S.;Kim, H.Y.;Kim, H.J.;Hong, S.M.;Ryu, S.Y.;Shin, Y.S.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2008.05a
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    • pp.370-373
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    • 2008
  • It is known that the temperatures of die, punch, holder and punch pad need to be kept different to get better formability in Mg sheet forming processes. Heating and cooling channels are usually equipped in each tool to assign different temperature. This study focused on the optimal design of the heating and cooling channels for a cross-shaped deep drawing die set. While the die and blankholder were heated to and kept at $250^{\circ}C$ by using heat cartridges, the punch and punch pad were kept at much lower temperature than that of the die and blankholder by water circulating through cooling channels. All the approaches were done by numerical analyses, aiming to maximize the cup height and to minimize the punch corner radius without any failure.

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A Numerical Analysis on Cooling Performance of Microchannel Waterblock for Electronic Devices Cooling (전자기기 냉각용 마이크로채널 워터블록의 냉각성능에 관한 수치해석)

  • Choi, Mi-Jin;Kwon, Oh-Kyung;Cha, Dong-An;Yun, Jae-Ho;Lee, Chan
    • Proceedings of the KSME Conference
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    • 2007.05b
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    • pp.2426-2431
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    • 2007
  • The microchannel waterblock has a good capability in the cooling of electronic devices. The object of this paper is to estiblish the scheme of design for the microchannel waterblock. The effects of flow rate and channel size on the cooling performances are investigated. It was found that the optimum flow rates were ragned from 0.7 lpm to 1.4 lpm. The thermal resistance at 2.0 lpm and 100 W was 0.13 $^{\circ}C$/W. Decrease in the width of channels is more effective for the improvement in the cooling performances of microchannel waterblock than increase in the height of channels. The increase of pressure drop resulted from decrease in the width of channels can be decreased by increasing the hight of channels.

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A Study on Design Automation of Cooling Channels in Hot Form Press Die Based on CATIA CAD System (CATIA CAD 시스템 기반 핫폼금형의 냉각수로 설계 자동화에 관한 연구)

  • Kim, Gang-Yeon;Park, Si-Hwan;Kim, Sang-Kwon;Park, Doo-Seob
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.19 no.3
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    • pp.147-154
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    • 2018
  • This paper focuses on the development of a support system that can rapidly generate the design data of a hot-form die with cooling channels, commonly known as hot stamping technology. We propose a new process for designing hot-form dies based on our (automated) system, whose main features are derived from the analysis of the design requirements and design process in the current industry. Our design support system consists of two modules, which allow for the generation of a 3D geometry model and its 2D drawings. The module for 3D modeling automation is implemented as a type of CATIA template model based on CATIA V5 Knowledgeware. This module automatically creates a 3D model of a hot-form die, including the cooling channels, that depends on the shape of the forming surface and the number of STEELs (subsets of die product) and cooling channels. It also allows for both the editing of the positions and orientations of the cooling channels and testing for the purpose of satisfying the constraints on the distance between the forming surface and cooling channels. Another module for the auto-generation of the 2D drawings is being developed as a plug-in using CAA (CATIA SDK) and Visual C++. Our system was evaluated using the S/W test based on a user defined scenario. As a result, it was shown that it can generate a 3D model of a hot form die and its 2D drawings with hole tables about 29 times faster than the conventional manual method without any design errors.

A study on the reduction of design variables for injection mold cooling system optimization (사출금형 냉각시스템 최적화를 위한 설계변수의 감소 방법 연구)

  • Choi, J.H.;Tae, J.S.;Rhee, B.O.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.05a
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    • pp.361-364
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    • 2009
  • The cooling system optimization for injection molds was studied with a response surface method in the previous research. It took so much time to find an optimum solution for a large product due to an extensive amount of calculation time for the CAE analysis. In order to use the optimization technique in the actual design process, the calculation time should be much reduced. In this study, we tried to reduce the number of design variables with the concept of the close relationship between the depth and the distance of cooling channels. The optimum ratio of the distance to the depth of cooling channels for a 2-dimensional problem was 2.0 so that the optimum ratio was again sought out for 4 industrial products. The major cooling effect of the injection molds for large products rely on baffle tubes. The optimum ratio of the distance to the depth for baffle tubes was 2.0 for the large products. The result enables us to reduce the number of the design variables by half in the cooling system optimization problem.

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Thermal managing effects by cooling channels on performance of a PEMFC (냉각채널 열관리에 따른 고분자연료전지의 성능영향 연구)

  • Sohn, Young-Jun;Kim, Min-Jin;Park, Gu-Gon;Kim, Kyoung-Youn;Lee, Won-Yong
    • 한국신재생에너지학회:학술대회논문집
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    • 2009.06a
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    • pp.373-373
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    • 2009
  • Relative humidity, membrane conductivity and water activity are critical parameters of polymer electrolyte membrane fuel cells (PEMFC) for high performance and reliability. These parameters are closely related with temperature. Moreover, the ideal values of these parameters are not always identical along the channels. Therefore, the cooling channel design and its operating condition should be well optimized along the all location of the channels. In the present study, we have performed a numerical investigation on the effects of cooling channels on performance of a PEMFC. Three-dimensional Navier-Stokes equations are solved with the energy equation including heat generated by the electrochemical reactions in the fuel cell. The present numerical model includes the gas diffusion layers (GDL) and serpentine channels for both anode and cathode gas flows, as well as cooling channels. To accurately predict the water transport across the membrane, the distribution of water content in the membrane is calculated by solving a nonlinear differential equation with a nonlinear coefficient, i.e., the water diffusivity which is a function of water content as well as temperature. Main emphasis is placed on the heat transfer between the solid bipolar plate and coolant flow. The present results show that local current density is affected by cooling channels due to the change of the oxygen concentration and the membrane conductivity as well as the water content. It is also found that the relative humidity is influenced by the generated water and the gas temperature and thus it affects the distribution of fuel concentration and the conductivity of the membrane, ultimately fuel cell performance. Unit-cell experiments are also carried out to validate the numerical models. The performance curves between the models and experiments show reasonable results.

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Fabrication and Testing of Injection Mold for Cosmetic Container with Conformal Cooling Channels Using Vacuum Diffusion Bonding (진공확산접합을 이용한 형상적응형 냉각채널을 가진 화장품 용기용 사출금형의 제작 및 시험사출)

  • Yu, Man-Jun;Park, Jong-Cheon
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.19 no.3
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    • pp.92-98
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    • 2020
  • In this study, an injection mold with conformal cooling channels was designed and manufactured for use in the production of a thick plastic cosmetic container that required high gloss surfaces. A cooling analysis verified the design of the conformal cooling channel for the cosmetic container, and also showed that the cooling efficiency was superior to that of the straight cooling channel. Slide cores designed with the conformal cooling channel were manufactured using the Layers Parting method and vacuum diffusion bonding. Subsequent test injection and quality inspection showed no problem in the appearance and dimensional accuracy of the produced product. The cycle time for product production was about 110 seconds, sufficient for mass production.