This paper discusses the results obtained from studies on the performance of different cooling layouts. The conventional method of cooling makes use of straight-line cooling channels. This simple ...method of cooling does not possess the capability of uniformly cooling down the part produced. In contrast, conformal cooling is a technique that makes use of cooling channels in an injection moulding tool that closely follows the geometry of the part to be produced. The paper presents some experiences gained in a comparative case study of conventional cooling vs conformal cooling using simulation, followed by an experimental validation and statistical analysis of the results.
3D-Mold'ed In-Security Parker, Grant; MacDonald, Eric; Zinner, Theo ...
Proceedings of the 8th ACM on Cyber-Physical System Security Workshop,
05/2022
Conference Proceeding
Additive Manufacturing (AM) - or 3D printing - is increasingly used to produce safety-critical components through the direct and indirect manufacturing of functional parts. The latter of which is ...achieved by creating molds or mold inserts for various casting techniques. While the security of direct manufacturing using AM has been extensively studied, the security of indirect manufacturing using AM, the sole focus of this paper, has not been considered before. In this paper, we concentrate exclusively on the sabotage security threat concerning mold design and manufacturing. Based on our performed analysis of achievable effects and identified viable attack methods that can be used, we determine that while some aspects are similar between direct and indirect manufacturing, there are distinct characteristics of indirect manufacturing.
In this study, an experimental research
has been carried out for the production of plastic injection molds with
conformal cooling channels by laminated brazing. In order to increase the
efficiency of ...the cooling system, conformal cooling channels are designed. Mold
cores and cavities were cut into layers and machined into plates. The plates
are combined with vacuum brazing method to produce plastic injection mold with conformal
cooling channels. The production of plastic parts was tried with two molds with
conformal and straight cooling channels. According to the results, both the
cycle time and the preparation time of the plastic injection mold for
production were shortened by the use of conformal cooling channels.
The work presented is a comparative analysis between a mould tool with multi-material and one with single-material structure by simulation of filling process. It is focused on benefits, accompanied ...by installing mould tools with multi-material structure. Defined are basic advantages and potentialities for design of such moulds.
Traditional cooling fails to fit the geometric outline of a product, thus limiting its cooling effect. Conformal cooling, on the contrary, generates an even cooling effect and demonstrates its ...advantages concerning complex models. A 3D metal printing technique was employed in the current study to make the mold core. The current study, combining the results from the CAE simulation and the real experiment, aimed to compare the cooling efficiency between baffles cooling and conformal cooling. It has demonstrated that conformal cooling has higher cooling efficiency. Residual stresses were measured by the photoelasticity instrument, the results revealed that conformal cooling residual stresses was lower than baffles cooling. In terms of cooling time, conformal cooling required 24 seconds, which 19.7% less than the baffles cooling one of 30 seconds.
In this paper, ANSYS Workbench is used to execute a heat-fluid coupling simulation of the improved cooling channel system, and the synergistic effect of the two channels is used to analyze the ...influence of cooling flow rate and temperature on the mold surface temperature varies during the heat transfer process. The results show that the higher the cooling flow rate, the faster the mold cavity surface temperature decreased; as the coolant temperature decreased, the local cooling rate increased. Compared with the traditional cooling, the mold temperature distribution uniformity of conformal cooling was much better. When the coolant temperature at 12°C and flow rate at 10 l/min, the mold cavity surface temperature discrepancy is the smallest, and the temperature uniformity was improved by 52.8%. Along with the temperature monitoring experiment, the calculated data was mapped by MATLAB, and experimental results were basically the same as the simulation results. At the same time, it provided theoretical references for actual production.
Dies for high pressure die casting are normally manufactured by machining of slabs of tool steel to the required dimensions. This manufacturing requires several steps such as rough machining, ...heat-Treatment, EDM (electro discharge machining) and polishing. With the AM (additive manufacturing) method SLM (Selective Laser Melting) it has become possible to print the dies fully or in part. Several advantages are expected, such as a better thermal distribution in the die in service and thereby extended die life and better component quality. This is due to the possibility of making the cooling channels conformal. There are also expectations of reduced time and cost in the manufacturing process due to fewer manufacturing steps and better material utilisation. Hopes are to print a net shape or near net shape that can be used directly as a die component. In this paper it is investigated to what extent this can be fulfilled by printing two die inserts to be used for casting fatigue test samples of aluminium. They were printed on a 3D Systems ProX DMP 300 in maraging steel powder. The result is that it is possible to obtain a sufficiently smooth surface die surface. However, the current design with an SLM insert fitted in a machined die makes extensive post printing manufacturing necessary.
PET bottle is an excellent packaging material, is widely used in the food & beverage industry which has further given impetus to the market. With an increasing demand for production capability of PET ...bottle, the rapid cooling efficiency and uniform temperature distribution are important issue on cooling channel design of blow mold. Due to the insufficient cooling time and non-uniform mold temperature distribution that cause bottle stress cracking or broken. In this study, the conformal cooling channel design is developed to achieve a rapid cooling efficiency and uniform temperature distribution of blow mold. The cooling efficiency and temperature distribution during cooling process was measured using infrared thermal image system and thermocouple sensor. Simulation technology was also developed by integration of thermal and fluid flow analysis modules of ANSYS-FLUENT. For cooling efficiency comparison, the shape and size of the conformal cooling channels, fluid temperature and flow rate were varied for both experiments and simulations. The capability and accuracy of simulation on conformal cooling channel design and analysis were verified via experiments. The simulated cooling efficiency and temperature distribution show reasonable agreement with measured results. A reduction in cooling time from the initial 2.9 seconds to 1 second; moreover, conformal cooling channel provides uniform temperature distribution and less temperature difference of 4°C.
Hlađenje alata za injekcijsko prešanje polimera izrađenog obradom odvajanjem čestica ima ograničenja, jer su kanali za hlađenje sastavljeni od uobičajenih ravnih rupa. Aditivnom tehnologijom mogu se ...izraditi rashladni kanali koji su prilagođeni kalupnoj šupljini. Ta vrsta rashladnih kanala naziva se konformni rashladni kanali. Konformni rashladni kanali mogu znatno smanjiti vrijeme ciklusa proizvodnje pri injekcijskom prešanju i znatno poboljšati kvalitetu proizvoda. U ovom istraživanju su dizajnirani i analizirani konformni rashladni kanali kao zamjena za konvencionalne kanale u alatu za injekcijsko prešanje. Pored uobičajenih ispitivanja izvršena je simulacija hlađenja, uspoređujući konvencionalnu i predloženu tehnologiju hlađenja. Rezultati su potvrđeni i testiranjem prototipa s konformnim rashladnim kanalima, pokazujući značajno poboljšanje u smanjenju vremena, više od 40 %.
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