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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMouldsSchoolofTechnologyandManagement,PolytechnicInstituteofLeiria
CoolingSystemsinInjectionMoulds1
The main phases in an injection moulding process involve
filling, cooling
andejection.Thecoolingphaseisthemostsignificantstepamongstthethree.Itdetermines
the rate atwhich the parts are produced. In themoment of
themeltedpolymer injection, ideally, themoulds temperature shouldbe
likeof
themeltedpolymerstemperatureandinthemomentofthepartsremovalthemouldmusttobe
to the temperature of the environment. Of thisway, the polymerwould
beinjectedwith theminimum of pressure and the difference between
the surfacetemperature and thenucleus temperatureof the
injectedpartswouldbe aminimum leading a slow cooling andminimising
themouldings stresses.Notice thatthese technical advantages are not
compatible with economical needs and thegeneralizedrule
istoproducepartswiththebiggestpossiblespeed.Accordingtothisrule,
themost important factor is thecapacityof
thecoolingsystemremovesheatofthecavitiesofthemould.Usuallythetimeofcoolingisaround50%ofthetotalcycle.The
injectedmaterial loses temperature in thecontactwith
themouldsurfaces,transferringitselfheatthroughthemould.Forspeedingtheheattransferprocess,
themoulddesignerdesign specificholes in the adjacent surfaces of
themouldedpartinthemould.Theseholes,knownbylinesofwater(bythewateristhemorefrequentfluidofcooling),constitutethecoolingsystemofamould.
Thefundamentalrulesthatshouldbehadincountinthecoolingsystemdesignare:
Introduction
i)The circuitsof thewater shouldbe symmetricaland independent
relativelytothefillingzonesandimpression(s)ofthemould;
ii) Thermal variations in thewalls of the impressions shouldnt
be
pronounced,sothelinesofwatershouldbedesignedinfunctionofitsdistancetotheimpressionwalls;
iii) The cooling fluid input and output should be placed for
themouldbackwards (opposite side to the operator), or alternative
for the breakslower;
iv)Itsimportanttoguaranteethatthecoolingflowinthechannelsbeturbulent.TheindexofturbulenceisgivenbyReynoldsnumber:
m
e
dvR =
Where,
vFlowsspeeddChanneldiameterFluiddensity
Dynamicviscosityofthefluidm
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CAEDSMouldandDieDesign
HeatTransferWhenitproceedstothepolymerinjectionforinsidetheimpressionofamouldtheremoval
energy of thepolymer in themelted state is transmitted by
conductionthrough themouldmaterialup to the channelsof the cooling
system and to
themouldexternalsurface.Theheatexchangemechanisms(fig.1)includetheconductionforthestructureoftheinjectionmouldingmachine,theforcedconvectionforthe
fluid that circulates into the cooling channels and the thermal
radiation
andnaturalconvectionfortheairthatsurroundthewallsofthemould[1,2].
Figure1Heatexchangeinamouldofinjection
EnergyBalanceIntheinjectionmouldingcycle,theheatcorrespondingtotheenthalpyvariationofthemouldingmaterialduringthecycle,isexchangedforthemouldingzonesurface(or
impressionsurfaceofthemould)andofthisforhisoutside.Todefinetheenergy
swing, is established an equilibrium between the heat powers that
areintroduced in themould, theheatpoweraccumulated
ineverysinglemoment intheir interior and the heat powers removed
from themould, being positive
ornegativethosethatrespectivelyincreaseordiminishtheirinternalenergy[1,3].Inaprocess
analysiswith accumulationof internal energy, theheat flow that is
suppliedtothemouldandtheheatflowthatisremovedfromthemouldshouldbeinthermal
equilibrium, in every singlemoment,with the heat accumulated in
thestructureofthemould:
CoolingSystemsinInjectionMoulds2
PL
Q + + = ACCUM
QAMB
Q TM
Q
PL
Q Heatflowsuppliedbythepolymer
AMB
Q
Heatflowtransferredfortheenvironment
TM
Q Heatflowtransferredforthecoolingfluid
ACCUM
Q Accumulatedenergyinthemouldmaterialpertimeunit
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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMoulds3
Simplifiedhypothesestoobtainresults
i)Quasistaticprocess
ii)During the cycles the temperaturesand thermal flows
fluctuationsaredespised
iii)Duringthedifferentperiodsmediumvaluesareconsidered
PL
Q + + =0AMB
Q TM
Q
Where,
arref
PLPL t
mh=Qarref
PLPL t
Vh = Q or,
Where,
;hh = hi- he i Polymerenthalpyattheinjectiontemperature;he
Polymerenthalpyattheejectiontemperature;m
Polymermassinjectedinthemould;PL
PLPolymermediumdensitybetweentheinjectiontemperatureandtheejectiontemperature;tarrefCoolingtimeoftheplasticpart;VVolumeoftheplasticpart
AMB
Q = + + CONV
Q COND
Q RAD
Q
Where,
CONV
Q Heatflowbyconvectiononthemouldlateralwalls
COND
Q Heatflowbyconductionontheinjectionmouldingwalls
RAD
Q Heatflowbyconductiononthemouldlateralwalls
CONV
Q =ALxhx(TambT )mould
Where,
A Mouldexposedarea;hHeattransfercoefficient,naturalconvection;TL
ambEnvironmentTemperature;TmouldMouldtemperature.
COND
Q =Afixxx(TambT )mould
Where,
AfixContactareaMould/Fixingsystem;Proportionalityfactor
RAD
Q
44100100
TmoldeTamb=ALxxradx
Where,
StefanBoltzmanconstant;Materialemissivityrad
When thematerial is inside themould cools supplying him heat, by
thatQPL
isalwayspositive.Theheatchangedwiththeenvironment,canbepositiveornegativedependingonthetemperatureofthemould.
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CAEDSMouldandDieDesign
CoolingConditions
An efficient system of cooling,with optimal cooling conditions,
leads to a partuniformdistributionof temperatures,minimizing
theundesired effects
appearedduringdecoolingprocess,thecycletimeandtherateofrejections.Theconceptionofanefficientcoolingsystemisnotasimpletrial,becausetherearedifferentfactorsthatcancontributeforthefinalintendedresults.Someofthefactorsthatinfluencethecoolingprocessare:thegeometryofthepart,thetemperatureofthemould,thearchitectureofthecoolingchannels,thecoolingfluidtemperatureandthespeedoftheflow.
Itcanbeidentifiedtworeferencetermsforaniterativeprocessofcharacterization
ofthemouldcoolingsystem[3]:
i)Theincreaseoftheheattransferrate
ii)Uniformtemperaturedistributioninthemouldingsurface
Whereas the increase of the heat removal rate between the
plastic part and the
mould is important in the economical point of view, the
uniformization of
thetemperaturesdistributiononthepartssurfaceswillprovidetheobtainingofpartswithestatesandqualityimproved.
CoolingTimeTheWubkenequationallowustoestimatethecoolingtime[3]
=
bW
aWK TT
TTst22
2 8ln
Where
CoolingSystemsinInjectionMoulds4
isthematerialthermaldiffusivity;s isthepartthickness;Ta
istheinjection temperature; Tb is the ejection temperature and Tw
is the medium mouldtemperature.
Themediummouldtemperatureisconsideredoneofthemostsignificantvariablesinthecoolingtimedetermination[4,5].Somedeterminationsusethetemperatureofthecoolingfluidforcalculatingthemediummouldtemperaturevariable.However,
such utilization ignores the temperature increases of the melted
plasticmaterialinthemoldingzones,duringtheinjectionphase.Duringthemoldingcyclethemould
temperature increasewhiletheplasticmaterial is
injected,diminishingprogressively up to the following
injection.Also the flow regime of the
coolingfluid,thetemperatureofthecoolingfluid,thearchitectureofthechannels,thekindofthecoolingfluid,andthemouldmaterialproperties(namelythemouldmaterialthermalconductivity),influencethemouldtemperature.
Table1Propertiesofatypicalresin,Aluminiumandsteel,usedinthemanufactureofinjectionmoulds.
SL Vantico 5260
Aluminium Steel P20 AlZn5Mg3Cu
Young modulus 600 - 800 MPa 72 MPa 2500 GPa Tensile strength 40
- 65 MPa 540 MPa 965-300 MPa Thermal conductivity 0.2 W.m-1 -1K
120-150 W.m-1K-1 29-34 W.m-1 -1KCoefficient of thermal expansion
(at 20C)
10510-6 K-1 23,610-6 -1 K 12,810-6 -1 K
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CAEDSMouldandDieDesign
Ifthecoolingchannelsarentcorrectlydesigned(fig.2),thecoreandcavitymouldwalltemperaturecanbedifferent.Ifthereisastronggradientinthecavitybetweenthetwohalvesthepartmaywarpanddistortitsshape[68].
Sothetargetsthatacorrectcoolingsystemhastofollowaretheuniformityofthewalltemperatureandagradualreductionofthepolymertemperature,inordertofindacompromisebetween
thenecessityofreducingcycle timeandallowing
forthecrystallization.
Ejected part
Last layer to cool
warpage
or
internal stresses Qcore
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CAEDSMouldandDieDesign
Inthiscontext,thedistancebetweenthecoolingchannelsandthemouldingsurface(h)and
thedistancebetween cooling channels (e) are themainparameters
tobeconsidered,asshownintheschemeofthefigure3.
CoolingSystemsinInjectionMoulds6
molding
d
qmin
s/2
qmx
h
emould
Coolingchannels
Figure3Heatflowprofile[13].
Inthepracticalone,iscommontoconsider:e=2,5a3,5deh=0,8a1,5e
On the issue ofdimensional criteria indesigning cooling
channels,
threedimensionshavetobeconsidered:thediameterofthecrosssection(orthecrosssectionareaifnotcircular),thedistancebetweenchannelsandthedistancebetweenchannel
andwall of themould. Themain problems that arisewhen choosing
thesedimensions concerns thepressure lossesderived from the
choiceof thediameterand thedesignof thechannel.Aheating/cooling
relationship reported
inZollner[14]givesaguidelineonthechannelspositioning.Thisstatesthatthevalueresultingfromthesolutionoftherelationshipshouldstaybetween2.5and5%forsemicrystallinethermoplasticsandbetween5and10%foramorphousthermoplastics.
ConformalCooling
In the injectionmoldingprocess themainpartof thecycle time
isdeterminedbythecoolingprocess.Therefore,itisimportanttooptimizethecoolingcycleinordertoreducethecoolingtime.Conformalcoolingchannels(i.e.channelsthatfollowthegeometricshapeofthepart)havebeenusedforthispurposeallowingasignificantcoolingtimereduction.AccordingtoWohlers[15]itispossibletoreducethecooling
cycle by 20% using conformal cooling channel. Similarly, Dimla et
al. [10]considers that cycle time can be significantly reducedwith
cooling taking placeuniformly in all zones if the cooling channels
aremade to conform to
thepartsshapeasmuchaspossible.Someinvestigationshaverelatedthemouldscycletimereductionwithconformalcooling;
themostrelevantresultassociated to itsuse
isthemouldsurfacetemperatureuniformity.Furthermore,ifthepartisejectedwiththesametemperatureineverypointthesubsequentshrinkageoutsidethemouldisalsouniform,whichavoidspostinjectionwarpageofparts.Thiswasalsopointedout
byVoet et al. [16],whichmentioned that the goal of cooling amould
is toobtain auniform temperature at themould surface andwithin the
final injectedproducttoavoidinternalstresses.
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CAEDSMouldandDieDesign
Amethodthatutilisesacontourlikechannel(fig.4),constructedascloseaspossible
to the surface of themould to increase the heat absorption away
from
themoltenplastic,ensuresthatthepartiscooleduniformlyaswellasmoreefficiently.
Figure4Conformalcoolingchannels
Whenmoltenplasticisinjectedinthemoulditmustbesolidifiedtoformtheobject.Themouldtemperatureisregulatedbycirculationofaliquidcooler,usuallywateroroilthatflowsinsidechannelsinsidethemouldparts.
Table2Heatconvectioncoefficientoftheair,waterandoil.
Air Water Oil HeatconvectioncoefficientWm2k1
50 900 400
Whenthepart issufficientlycooled
itcanbeejected.Most(95%)oftheshrinkagehappensinthemouldanditiscompensatedbytheincomingmaterial;theremainderoftheshrinkagetakesplacesometimefollowingtheproductionofthepart[17].
Ifthechannelscarryingthewatercouldbeconformedtotheshapeofthepartand
their cross section changed to increase the heat conducting area
then a moreefficientmeans of heat removal could be realised.Thismay
also help to
reducewarpagewhenthepartisejected,astheplasticwouldbecooledmoreuniformly.
Anotheradvantageisthatamouldequippedwithconformalchannelsreachestheoperation
temperature quicker than a normal one equipped with standard
(ordrilled)coolingchannels[18,19].
Modelling
The analysis toolsutilization for the cooling systems conception
that assures
theuniformityofthecoolingalongthepart,drivethesignificantimprovementsinthemouldproductionanddefinitionof
theprocessconditions to thespecificationsoftheproductdemanded.
Themain resistance to the transferenceofheat in
thecoolinghappenof
theownmaterialduetothelowthermaldiffusivityoftheplasticmaterial.So,itsessentialtoconsiderthedependenceofthematerialwiththetemperatureinthemodulationoftheheatconduction.
CoolingSystemsinInjectionMoulds7
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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMoulds8
Inthecoolingprocessitsessentialtoconsiderthethermalpropertiesofthemouldmaterialandappropriateborderconditions(e.g.theheattransferbyforcedconvectioninthecoolingchannels).
Inisotropicdomaintheheattransferisdescribedbytheenergyconservationequation[20]:
( ) += QTK
tTCP
Where,CPandkrepresentthedensity,thespecificheatandthethermalconductivity
of the material, respectively. T represents the local temperature
in each
instantmomenttand ineachspatialcoordinate,whereas
representstheenergygenerated/dissipatedbyunitof
timeandbyunitofvolume in thematerial.
Thisdifferentialequationwithderivedpartial
forbidimensionalheatconduction,notstationary,inCartesianscoordinatesandinasimplifiedform,takestheform:
Q
+
+
=
QyTK
yxTK
xtTCP
Thetemperatureprofile
inagivenzoneofthematerialandhisvariationwiththetimeareabletobeobtainedresolvingthisequation.However,itisnecessaryspecifythetemperatureprofileintheinitialinstantandtheborderconditions.
Tooptimise thedesignandconstructionof themould,withattentionon
refiningthe tooldesign through application of finite element and
thermal flow analyses,specific commercial software for
injectionmouldinghave beenused. In thenextsection
itwillbemadeabriefdescriptionabouttheheattransferprocessanalysisusingsomecommercialsoftware.
ThelatestcommercialsoftwareofCAEallowsthreedimensionalsimulationoftheinjection
molding process. This software has modules for conception
efficientcoolingsystems.Thecoolinganalysisisbasedinthemethodoftheborderelementsapproach.
InthecoolingmoduleofthecommercialCAEsoftware,thetransferenceofheatinthepolymer
is treatedasonedimensionalconduction located in
transientregime.Theheatexchangebetweenthesurfaceofthecoolingchannelsandthecoolingfluidareconsidered
instationaryregime,consideringthecorrelationfortheheattransferencecoefficientbyconvection.Tosolvesimultaneouslytheprominentequationsoftransferenceofheatinthisprocess,theprogramutilizesahybridschemewherethe
transference of heat is calculated by the approachmodified analyzes
of theelement of three dimensional border for the region of the
mould, and onedimensionalheat transferenceanalysis,along thepart
thickness for the
regionofmeltedplastic.Thesetwoanalysesareconjugatedofformitequalthetemperatureandtheheatflowintheinterfacepolymer/mould.
Coolingsystemsimulation
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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMoulds9
Theequationsfortheflowofthefluidinacircuitofcoolingareresolvedthroughthe
iterative approach ofNewtonRaphson, to obtain the torrent and the
fall
ofpressureineachchannelofthecoolingsystem.Then,theheattransferencecoefficientsbetweenthesurfacesofthechannelsandthecoolingfluidarecalculated.
Thechangeofheatbynaturalconvectionbetweentheenvironmentandthewallsofthemouldarealsocalculated.Forthiscalculation,commercialsoftwareconsiderstheexteriorsurfaceofthemouldasaspherewithanareaequivalenttothesurfaceofabox,inthatthechannelsofcoolingwillbeincluded,thefeedingsystemandthemoldingzones.
Theprocesssimulationstarts inthephaseofthemouldfilling.
Whenthecoolingmoduleof cooling isused, thepolymer injection
temperature isassumedasconstant. This assumption has some
associated errors; therefore the injectiontemperature can be a
superior due to the heating by viscous dissipation of
thematerialinthesprue.Thattemperaturewouldbeabletogoupuntil30Cdependingonthespeedofinjectionandofthematerialproperties[21].
The thermal resistance in the interfacepolymer/moulddefines
theheat
transmissioncoefficient(hint)intheinterfacebetweenthepolymerandthemoldingsurfaces.Thiscoefficientisusedforsimulatetheresistancetotheexistingheatinthecontactbetweenthetwomaterialsbythefollowingequations:
CAESoftwareSimplifications
( )bx
bxM nTkTTh
==
=intint
( )bx
bxM nTkTTh
+=+=
+
=intint
where,Tintisthemelttemperatureintheinterfaceofthetwomaterials;
and
arethemoldingzonestemperatures,onthecavityside(negativeside)andonthecoreside(positiveside),respectively.Theindicesband+bindicatethepositiveandnegativesideofthedistancerelativelytothecenterofthepart(equivalentthehalfofitsthickness).
MT
+MT
If the thermalconductivityassumes thezerovalue, (thermal
isolatedborder), thechangesbetween the twomaterialsdonotexist. If
itassumesanelevatedvalue,existaperfectthermalcontactbetweenthematerialsandtheinterfacetemperatureis
considered equivalent at the mould wall temperature. Many times,
and bydefect,thisvalueisof25000w/m2C,incommercialsoftware.
The case study presented shows some important
aspectswhendifferent coolingsystemsareconsidered.
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CAEDSMouldandDieDesign
CaseStudy
Figure5Coolingsystemcasestudy.
Coolingsysteminthecavityside
a)Conventionalcoolingsystem
Figure6Temperaturedistributiononthepartssurfaces
Figure7Partsdeflection
Figure8Partscoolingtime Figure9Percentagefrozenlayer
CoolingSystemsinInjectionMoulds10
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CAEDSMouldandDieDesign
b)Bafflecoolingsystem
Figure10Temperaturedistributiononthepartssurfaces
Figure11Partsdeflection
Figure12Partscoolingtime Figure13Percentagefrozenlayer
c)Conformalcoolingsystem
Figure14Temperaturedistributiononthepartssurfaces
Figure15Partsdeflection
Figure16Partscoolingtime Figure17Percentagefrozenlayer
CoolingSystemsinInjectionMoulds11
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CAEDSMouldandDieDesign
Coolingsysteminthecavityandcoresides
a)Conventionalcoolingsystemsinthecavityandcoresides
Figure18Temperaturedistributiononthepartssurfaces
Figure19Partsdeflection
Figure20Partscoolingtime Figure21Percentagefrozenlayer
b)Bafflecoolingsystemsinthecavityandcoresides
Figure22Temperaturedistributiononthepartssurfaces
Figure23Partsdeflection
Figure24Partscoolingtime Figure25Percentagefrozenlayer
CoolingSystemsinInjectionMoulds12
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CAEDSMouldandDieDesign
c)Conformalandbafflecoolingsystemsinthecavityandcoresides,respectively
Figure26Temperaturedistributiononthepartssurfaces
Figure27Partsdeflection
Figure28Partscoolingtime Figure29Percentagefrozenlayer
d)Conformalcoolingsysteminthecavityandcoresides
Figure30Temperaturedistributiononthepartssurfaces
Figure31Partsdeflection
Figure32Partscoolingtime Figure33Percentagefrozenlayer
CoolingSystemsinInjectionMoulds13
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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMoulds14
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CAEDSMouldandDieDesign
CoolingSystemsinInjectionMoulds15
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Cooling Systems in Injection Moulds Case StudyCooling system in
the cavity side Cooling system in the cavity and core sides
References