2012 Moldex3D R11 European Webinar Series

Conformal Cooling Industrial Application and Design Optimization Technology

Definition

Con-for-mal

adj.

1. :Leaving the size of the angle between corresponding curves unchanged

2. of a map: representing small areas in their true shape Origin: Late Latin conformalis having the same shape, from Latin Com- + formalis formal, from forma First known use: 1893

Source:/www.merriam-webster.com/dictionary
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Dr. Andrew Hsu

Current position:
CoreTech System senior engineer

Education:
Ph.D. of Mechanical engineering in University of California, Davis

Research area:
Aerodynamics, heat transfer, numerical analysis, advanced injection molding process (conformal cooling, GAIM/WAIM
Dr. Hsu joined CoreTech System (Taiwan) in 2010. His recent research is focus on CAE and several advanced injection molding fields such as gas/water assisted injection mold, injection compression molding, optical parts, and conformal cooling. Dr. Hsu has several years teaching experience in professional fields such as heat transfer and injection molding. He have assisted several famous injection molding manufacturers to solve real industry cases worldwide. His teaching combines theories and practical cases which offers a thorough understanding for those from novice to experienced professionals in injection molding field.
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Contents
> Introduction
What and why is conformal cooling Benefits

> Mold Heat Transfer

Conduction, Convection, Radiation

> Conformal Cooling Design and Manufacturing

Design
Manufacturing: laser sintering and vacuum brazing

> CAE Analysis on Conformal Cooling > Case Study

Carriage model Cup model

> Summary

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Introduction

Injection Molding Procedures

Cooling Stage

Mold open/Ejection Mold Close Screw moves forward Filling Stage

Packing Stage

Nozzle shut off Screw moves backward

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Advanced Injection Molding Processes

> Goals: Shorten cycle time Material saving Quality improvement

Gas/Water assisted injection molding - Weight reduction(~40%), improve product quality, reduce cooling time Conformal Cooling - Reduce cooling time (20-60%) - Improve product quality Variotherm - Improve product quality

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Cooling channel design

Q:Whats the best design for these products?

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Introduction of Conformal Cooling

> What is conformal cooling?
Cooling channel design based on product contour.

> Why is conformal cooling?

To increase cooling efficiency. With conformal cooling, cooling rate difference can be minimized through the whole part. To reduce cycle time and cost To have better product quality

Source: EOS whitepaper, Siegfried Mayer (EOS GmbH) 99

Introduction of Conformal Cooling

> When to use conformal cooling?
For products with complex geometry. In order to remove heat from areas where traditional tooling method can not reach.

> How to manufacture conformal cooling channels?

DMLS (Direct Metal Laser-Sintering) and vacuum brazing methods are usually applied. Traditional drilling method may have problems in manufacturing conformal cooling system.

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Introduction of Conformal Cooling

> Some examples

From http:\\\www.3dinnovation.dk/conformal_cooling_eng.htm
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What are the benefits of conformal cooling?

> Problems on polymer molding Sink mark Warpage Cycle time

> Use conformal cooling during the injection molding process to: Improve product quality such as warpage and sink mark Decrease cycle time

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Mold Heat Transfer

The importance of heat dissipation

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Cooling system components

> Contains components like: Mold Temperature Controller

Regular Channel
Manifold Hose OthersBaffle or Bubbler
Insulated

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Mold Heat Transfer

> Heat Transfer Modes:

Conduction Convection Radiation

> Heat Transfer Considered in Injection Molding:

Heat removed from cavity to mold base Heat removed from mold base to cooling channels Mold surface radiation Mold surface convection

Heat removed at ejection

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Heat Conduction and Convection

> Cooling system design and cooling time:
Heat Conduction between cavity and cooling channels (Fouriers Law):
dq dT q k T k Adt dx "

Heat convection equation inside cooling channels:

dq q hT h(T 4 T 3) Adt
Coolant Type Coolant velocity Cooling channel diameter b Coolant temperature h: conv. heat transfer coefficient Cavity b Cooling Channel

"

Mold base
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Conformal Cooling Design and Manufacturing

Cooling Channel Design Parameters

Three parameters on cooling channel design:
Distance between pipe and cavity: c Distance between pipes: a Pipe diameter: b

Theoretically, c should be as smaller as possible. And the values of a and b are dependant. However, mold strength and lifecycle is a great concern. So, there is a experimental design guideline for the three parameters as shown in the table.
Source: EOS whitepaper, Siegfried Mayer (EOS GmbH) 19 19

Conformal Cooling Channel Design

Source: EOS whitepaper, Siegfried Mayer (EOS GmbH) 20 20

Conformal Cooling Manufacturing

Matsuura

Direct Metal Laser Sintering Machine

LUMEX Avance-25

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Conformal Cooling Manufacturing

LUMEX
Powder Supply
Repeat 10 times

Laser Sintering

10 times

Milling
Repeat

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Vacuum Brazing
> Brazing is a metal-joining process whereby a filler metal is heated above and distributed between two or more close-fitting parts by capillary action. > The filler metal is brought slightly above its melting (liquidus) temperature while protected by a suitable atmosphere, usually a flux. It then flows over the base metal (known as wetting) and is then cooled to join the workpieces together. It is similar to soldering, except the temperatures used to melt the filler metal are above 450 C (842 F). > Vacuum brazing is a materials joining technique that offers significant advantages: extremely clean, superior, flux-free braze joints of high integrity and strength.
Source: http://en.Wikipedia.org

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CAE Analysis on Conformal Cooling

Moldex3D Solution for Conformal Cooling

> For any complex cooling channel design. Meshing can be constructed in Moldex3D with ease. > STL format files can be imported and defined as cooling channel or heating rod in Designer.

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Moldex3D Solution for Conformal Cooling eDesign procedures

Step 1: import part and runner Step 4: generate mesh

Step 2: import .stl cooling channel Step 3: define attribute as cooling channel Step 5: export file for simulation

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Moldex3D Solution for Conformal Cooling Solid procedures

Step 1: import part and runner model in Rhino Step 4: construct BLM/hybrid solid mesh for cooling channels

Step 2: build runner/cavity solid mesh Step 3: import cooling channel file

Step 5: build mold base solid mesh Step 6: export solid model
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Moldex3D Solution for Conformal Cooling

> Cooling time and transient mold temperature can be estimated. The right figure shows the temperature animation.

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Moldex3D Solution for Conformal Cooling

> The flow properties (temperature, pressure, velocity) inside the cooling channels can be estimated in 3D.

R11 Solid only

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Moldex3D Solution for Conformal Cooling

Moldex3D can: Predict required coolant flow rate to fit production cycle time Predict possible pressure loss in your cooling channel design Prevent vortex/dead water area in your cooling channel design Simulate baffle/bubbler designs in a true 3D approach

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1. Carriage Model
> As shown in the figure below, the hallow interior of this part is the crucial area. With traditional cooling channel design, this is mostly the area with heat accumulation. This will cause inward warp during injection molding process.

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Cooling Channel Design

> The conventional design has no cooling channel inside the hallow interior. With conformal cooling design, warp can be reduced.

Conventional

Conformal
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Cooling Analysis Cooling Temperature

Conventional Cooling Conformal Cooling Cooling Temperature 60.650 ~ 114.647 Cooling Temperature 60.388 ~ 69.126

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Cooling Analysis Cooling Time

Conventional Cooling Conformal Cooling

Cooling Time

Cooling Time

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Cooling Analysis Cooling Efficiency

Conventional Cooling Conformal Cooling Cooling Efficiency

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Cooling Analysis Mold Temp Difference

Conventional Cooling Conformal Cooling Mold Temp Difference Mold Temp Difference

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Cooling Analysis -- Mould Temperature

> The two figures below show the mould temperature distribution of conventional and conformal cooling design. We can see the maximum temperature drops from 114.7 to 69.2

Conventional Cooling

Conformal Cooling

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Result Summary
> For this case, the z-direction warp is the most concerned point. Compare the conventional cooling system design with conformal design, z-direction warp reduced by 87%.

Conventional

Conformal

Improved (%)

-0.2512 ~ 0.2439 mm

-0.2585 ~ 0.2499 mm

-3

Y
Z

-0.113 ~ 0.133 mm
-0.677 ~ 0.655 mm

-0.098 ~ 0.12mm
-0.084 ~ 0.086 mm

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87

Total

0.001 ~ 0.685 mm

0.001 ~ 0.265mm

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Displacement comparison
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Result Summary
> From the photo of actual product, we can also see the warpage improvement is significant in z direction.

Conventional Cooling

Conformal Cooling

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2. Cup Model
Length 90 mm Width 90 mm Height120 mm Thickness 2 mm

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Product temperature -- Baffle

Temperature animation

Temperature range 75~103 EOC product surface temperature: 82~91

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Moldbase temperature -- Baffle

Temperature animation

Temperature range 79~105

EOC mold temperature range:79~91

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Temperature history at sensor nodes

Cooling rates at each node are not the same, this will affect product quality. EOC product surface temperature is 84~91 , temperature difference is 5~7 .

Flow

Pack

Cool

Open
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Product temperature -- Conformal

Temperature animation

Temperature range 75~98 EOC product surface temperature range: 80~82

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Moldbase temperature -- Conformal

Temperature animation

Temperature range 79~98

EOC Moldbase temperature:79~84

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Temperature history at sensor nodes

Cooling rates at each node are closer than traditional cooling. EOC product surface temperature is 80.5~81.5 , temperature difference is 2~3 .

Flow

Pack

Cool

Open
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Summary

Summary

> Conformal cooling is an effective way to shorten cycle time and improve product quality at the same time.
In carriage model:
warpage in z direction improve 87% cooling time shorten 61%. In cup model: cycle time reduction up to 42%

> Moldex3D can predict:

Transient mold/part temperature

Coolant physical properties

Cooling time and efficiency which is a useful tool for conformal cooling design validation.

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Thank you for your attention!

Contact Information

Dr. Hsu
andrewhsu@moldex3d.com

Larry
larryren@moldex3d.com

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