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Effect of conformal cooling design on residual stresses in injection molded parts
https://orcid.org/http://orcid.org/0000-0003-3399-5238
The widely utilized technique of injection molding results in residual stresses in manufactured products because of related heat and pressure fluctuations. This work assesses the effect of cooling channel design on residual stresses. Conformal cooling channels with various diameters, depths, and pitches were investigated using Taguchi technique. Residual stresses for straight and conformal cooling ducts were computed numerically. To validate simulation results, tensile tests were conducted on specimens obtained from a molded plastic part cooled with straight channels. Statistical analyses were conducted to establish the relationships between the cooling channel design variables and the residual stresses. For the mold used, the parameters that led to minimum residual stresses were a depth of 24 mm, a diameter of 12 mm and a pitch of 24 mm. A comparison of stresses resulting from straight and conformal cooling channels revealed that conformal cooling reduces residual stresses by over 40%. Numerically predicted maximum residual stresses were 21.44 MPa and 35.79 MPa for conformally and straight channel cooled parts respectively. The average experimental ultimate tensile stress for a part made with straight channels was 32.3 MPa. It is therefore deduced that since residual stress for the part made using conformal cooling is less than the UTS, the part is less likely to fail than that made using straight channels which has a higher residual stress than the UTS. Analysis of variance showed that the cooling channel diameter contributes most significantly to residual stresses at 89.3%. The findings of this study will guide injection mold designers in the development of molds for reduced residual stresses of the product, which will in turn help reduce flaws and improve productivity in injection molding.
Effect of conformal cooling design on residual stresses in injection molded parts
https://orcid.org/http://orcid.org/0000-0003-3399-5238
The widely utilized technique of injection molding results in residual stresses in manufactured products because of related heat and pressure fluctuations. This work assesses the effect of cooling channel design on residual stresses. Conformal cooling channels with various diameters, depths, and pitches were investigated using Taguchi technique. Residual stresses for straight and conformal cooling ducts were computed numerically. To validate simulation results, tensile tests were conducted on specimens obtained from a molded plastic part cooled with straight channels. Statistical analyses were conducted to establish the relationships between the cooling channel design variables and the residual stresses. For the mold used, the parameters that led to minimum residual stresses were a depth of 24 mm, a diameter of 12 mm and a pitch of 24 mm. A comparison of stresses resulting from straight and conformal cooling channels revealed that conformal cooling reduces residual stresses by over 40%. Numerically predicted maximum residual stresses were 21.44 MPa and 35.79 MPa for conformally and straight channel cooled parts respectively. The average experimental ultimate tensile stress for a part made with straight channels was 32.3 MPa. It is therefore deduced that since residual stress for the part made using conformal cooling is less than the UTS, the part is less likely to fail than that made using straight channels which has a higher residual stress than the UTS. Analysis of variance showed that the cooling channel diameter contributes most significantly to residual stresses at 89.3%. The findings of this study will guide injection mold designers in the development of molds for reduced residual stresses of the product, which will in turn help reduce flaws and improve productivity in injection molding.
Effect of conformal cooling design on residual stresses in injection molded parts
https://orcid.org/http://orcid.org/0000-0003-3399-5238
The widely utilized technique of injection molding results in residual stresses in manufactured products because of related heat and pressure fluctuations. This work assesses the effect of cooling channel design on residual stresses. Conformal cooling channels with various diameters, depths, and pitches were investigated using Taguchi technique. Residual stresses for straight and conformal cooling ducts were computed numerically. To validate simulation results, tensile tests were conducted on specimens obtained from a molded plastic part cooled with straight channels. Statistical analyses were conducted to establish the relationships between the cooling channel design variables and the residual stresses. For the mold used, the parameters that led to minimum residual stresses were a depth of 24 mm, a diameter of 12 mm and a pitch of 24 mm. A comparison of stresses resulting from straight and conformal cooling channels revealed that conformal cooling reduces residual stresses by over 40%. Numerically predicted maximum residual stresses were 21.44 MPa and 35.79 MPa for conformally and straight channel cooled parts respectively. The average experimental ultimate tensile stress for a part made with straight channels was 32.3 MPa. It is therefore deduced that since residual stress for the part made using conformal cooling is less than the UTS, the part is less likely to fail than that made using straight channels which has a higher residual stress than the UTS. Analysis of variance showed that the cooling channel diameter contributes most significantly to residual stresses at 89.3%. The findings of this study will guide injection mold designers in the development of molds for reduced residual stresses of the product, which will in turn help reduce flaws and improve productivity in injection molding.
Effect of conformal cooling design on residual stresses in injection molded parts
Int J Interact Des Manuf
Simiyu, Laura W. (Autor:in) / Mutua, James M. (Autor:in) / Muiruri, Patrick I. (Autor:in) / Ikua, Bernard W. (Autor:in)
01.03.2025
16 pages
Aufsatz (Zeitschrift)
Elektronische Ressource
Englisch
Injection molding , Conformal cooling channels , Straight cooling channels , Residual stress , Ultimate tensile stress Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
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