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A Holistic Approach to Cooling System Selection and Injection Molding Process Optimization Based on Non-Dominated

Janez Gotlih1, Miran Brezocnik1, Snehashis Pal1

  • 1Faculty of Mechanical Engineering, University of Maribor, Smetanova ulica 17, 2000 Maribor, Slovenia.

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Summary
This summary is machine-generated.

Conformal cooling in injection molding optimizes tool temperature for shorter cycle times and better product quality. A novel tool-efficiency index balances cooling performance with manufacturing considerations.

Keywords:
additive manufacturingconformal coolinginjection moldingnon-dominated sortingnumerical simulationtooling

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Thermal Engineering

Background:

  • Controlling tool temperature is crucial in injection molding for product quality and cycle times.
  • Traditional cooling channels often fail to effectively manage heat in critical tool areas.
  • Optimizing cooling systems requires balancing performance with manufacturing constraints.

Purpose of the Study:

  • To investigate the effectiveness of conformal cooling in injection molding for critical tool areas.
  • To develop a holistic approach integrating tool design, manufacturing, and process parameters.
  • To introduce and utilize a novel tool-efficiency index for multi-objective optimization.

Main Methods:

  • Numerical simulations of the injection molding process.
  • Multi-objective optimization incorporating four process cycle criteria.
  • Development and application of a tool-efficiency index with non-dominated sorting.
  • Experimental validation of simulation results.

Main Results:

  • Conformal cooling effectively cools critical tool areas, reducing cycle times and minimizing product warpage.
  • The tool-efficiency index revealed a trade-off between cooling performance and overall tool efficiency.
  • Optimization using the tool-efficiency index reduced the number of simulation cases to six.
  • Experimental validation confirmed the simulation findings for conformal cooling performance.

Conclusions:

  • Conformal cooling offers significant advantages in managing tool temperature and improving injection molding efficiency.
  • The tool-efficiency index provides a valuable metric for optimizing cooling system design and process parameters.
  • A holistic approach considering multiple factors leads to more effective tool design and process selection.
  • The study successfully demonstrated the practical application and validation of conformal cooling technology.