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Related Experiment Video

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High-Efficiency Surface-Cooled Rapid Tooling Development for Injection Molding of Low-Density Polyethylene.

Chil-Chyuan Kuo1,2, Pin-Han Lin1, Jing-Yan Xu1

  • 1Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 24301, Taiwan.

Polymers
|February 26, 2025
PubMed
Summary

This study introduces surface-cooled cooling channels (SCCCs) in aluminum-filled epoxy resin molds for rapid tooling. SCCCs significantly improve cooling efficiency by 58.7%, boosting production and reducing defects in injection molding.

Keywords:
Moldex3D simulationepoxy resin filled with aluminum particlesheat dissipation timeplastic injection moldingpolymer composite materialsurface-cooled cooling channels

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Area of Science:

  • Polymer Science and Engineering
  • Materials Science
  • Manufacturing Technology

Background:

  • Polymer composite materials, specifically aluminum-filled epoxy resin, are crucial for rapid tooling in product design.
  • Enhancing cooling efficiency in molds is vital for optimizing injection molding processes.

Purpose of the Study:

  • To develop and evaluate aluminum-filled epoxy resin molds with surface-cooled cooling channels (SCCCs).
  • To assess the impact of SCCCs on cooling performance, production efficiency, and defect rates in low-density polyethylene (LDPE) injection molding.

Main Methods:

  • Utilized Moldex3D simulation with a 1 mm mesh size for mold filling analysis.
  • Conducted experimental analysis to validate simulation results and determine optimal molding parameters.
  • Proposed a cooling mechanism for SCCCs in LDPE injection molding.

Main Results:

  • Simulations confirmed complete mold filling within 5 seconds.
  • Identified optimal parameters: 160 °C melt temperature, 30 °C mold temperature, 10 MPa injection pressure, and 20 s heat dissipation time.
  • SCCCs enhanced cooling efficiency by 58.7% compared to conventional conformal cooling channels.

Conclusions:

  • SCCCs offer superior cooling performance, reducing cycle times and increasing production capacity.
  • The developed SCCC technology minimizes energy consumption, carbon emissions, and product defects in large-scale manufacturing.
  • This advancement provides a more efficient and sustainable approach to rapid tooling in injection molding.