Abstract
Injection molds are production tools that require detailed analysis based on the quality of the resulting part, the impact on cycle times, and the expected production volume. Cooling channels also play a critical role in mold performance and product quality as they largely determine cycle time. Designs that incorporate conformal cooling channel (CCC) geometries that conform to or align with the part contour are currently being explored as an alternative to conventional cooling channel designs in injection molds. In this study, a simulation of CCC geometries was performed and their effects on mold temperatures and warpage were investigated. Two cross-sectional geometries, circular and square, were selected for a three-factor level design of experiments (DOE) analysis. The response variables used were mold temperatures and part warpage. A cup-shaped part with upper and lower diameters of 54 and 48 mm, respectively, a height of 23 mm and a thickness of 3 mm was used for the injection molded part. A comparison was also made between two materials for the injection mold, steel and polycarbonate. The DOE results showed that the distance between the CCC and the injected part and the diameter or side of the square have significant effects on the response variables for both systems (steel and polycarbonate molds). In addition, a comparison between conventional and conformal cooling channels was analyzed using a cup-shaped part and a less rigid part geometry. The finite element simulation results show a 9.26% reduction in final warpage in the cup-shaped part using CCCs compared with the conventional cooling methods in steel. When using parts with lower geometry stiffness, the use of CCCs reduced final part warpage by 32.4% in metal molds and by 59.8% in polymer molds.