Finite element cooling simulations of conformal cooling hybrid injection molding tools manufactured by selective laser melting

Finite element cooling simulations of conformal cooling hybrid injection molding tools manufactured by selective laser melting

This paper presents an application of additive manufacturing (AM) technology that is suitable for manufacturing injection molding tools with conformal cooling channels to increase productivity. The design and the manufacturing of a hybrid injection molding insert by combining machining and selective...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology Vol. 103; no. 5-8; pp. 2515 - 2522
Main Authors: Abbès, Boussad, Abbès, Fazilay, Abdessalam, Hichem, Upganlawar, Aditya
Format: Journal Article
Language:English
Published: London Springer London 01-08-2019
Springer Nature B.V
Subjects:
CAE) and Design
Channels
Computer-Aided Engineering (CAD
Cooling
Copper base alloys
Cycle time
Engineering
Finite element method
Industrial and Production Engineering
Injection molding
Laser beam melting
Laser cooling
Lasers
Machining
Manufacturing
Mathematical analysis
Mechanical Engineering
Media Management
Original Article
Rapid prototyping
Injection molding
Additive manufacturing (AM)
Conformal cooling
Selective laser melting (SLM)
Finite element simulation
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Description
Summary:This paper presents an application of additive manufacturing (AM) technology that is suitable for manufacturing injection molding tools with conformal cooling channels to increase productivity. The design and the manufacturing of a hybrid injection molding insert by combining machining and selective laser melting (SLM) technologies was analyzed. A simplified finite element cooling analysis was used to compare conventional and hybrid solutions for the design of cooling channels to decrease the injection cycle time of an automotive plastic part. The simulation results showed that, by using a hybrid steel/high-conductivity copper alloy with conventional cooling for the design of the mold insert, the injection cycle time can be reduced by 50.3%, and by using hybrid steel/steel with conformal cooling, the injection cycle time can be reduced by 65.6%. The hybrid injection molding insert with conformal cooling made by selective laser melting (SLM) technology was successfully tested under real production conditions confirming the significant reduction of the injection cycle time.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-019-03721-2