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Related Concept Videos

Stress Concentrations01:24

Stress Concentrations

283
Stress concentration is when stress intensifies near discontinuities such as holes or abrupt cross-sectional changes in a structural member. This localized stress can often surpass the average stress within the member. The stress distribution in flat bars, either with a circular hole or varying widths connected by fillets, can be determined experimentally using a photoelastic method. The results are based on ratios of geometric parameters like the ratio of the hole's radius to the smaller...
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Stress Concentrations in Circular Shafts01:18

Stress Concentrations in Circular Shafts

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Consider the elastic torsion formula, which applies to a circular shaft with a consistent cross-section. This formula assumes that the shaft's ends are loaded with rigid plates firmly attached. However, in many cases, torques are applied to the shaft through mechanisms like flange couplings or gears, which are connected by keys inserted into keyways. This application method modifies the stress distribution near the point of torque application, causing it to deviate from the distributions...
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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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The Impact of Surface Roughness on Conformal Cooling Channels for Injection Molding.

Jan Hanzlik1, Jiri Vanek1, Vladimir Pata1

  • 1Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic.

Materials (Basel, Switzerland)
|June 19, 2024
PubMed
Summary

Reducing surface roughness in additive manufactured conformal cooling channels by 90% lowers coolant pressure by 0.033 MPa. This improves injection molding efficiency and product quality by optimizing coolant flow dynamics.

Keywords:
ADAMDMLSadditive manufacturingconformal cooling channelsinjection moldingregressionsurface roughness

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Additive Manufacturing

Background:

  • Injection molding is vital for complex components but faces quality challenges.
  • Conformal cooling channels enhance injection molding efficiency.
  • Additive manufacturing (AM) enables complex channel geometries.

Purpose of the Study:

  • To investigate the impact of surface roughness on conformal cooling channel efficiency.
  • To compare surface roughness and flow characteristics between Direct Metal Laser Sintering (DMLS) and Atomic Diffusion Additive Manufacturing (ADAM).
  • To establish quantitative relationships between surface roughness and coolant flow parameters.

Main Methods:

  • Experimental analysis of surface roughness using profilometry and scanning electron microscopy.
  • Cooling system flow analysis to measure coolant pressure, Reynolds number, and flow velocity.
  • Development of regression models to correlate surface roughness with flow parameters.

Main Results:

  • Significant differences in surface roughness were observed between DMLS and ADAM.
  • Reduced surface roughness (up to 90%) led to a 0.033 MPa decrease in coolant media pressure.
  • Surface roughness directly influences coolant flow dynamics and pressure distribution.

Conclusions:

  • Surface roughness is a critical factor in the performance of AM-produced conformal cooling channels.
  • Optimizing surface roughness through technology selection and post-processing enhances cooling efficiency.
  • Findings provide insights for improving injection molding cooling systems and product quality.