Abstract
Rapid tooling (RT) and rapid manufacturing (RM) technologies have demonstrated the potential to manufacture injection molds with cooling channels, which are conformal to the molding cavity. This article presents a study involving fabrication of square cross sectional conformal cooling channel (SCSCCC) using laser based rapid manufacturing process of Direct Metal Deposition (DMD). The DMD process can be used for fabrication of conformal cooling channels of different cross section and of different configuration. For optimization of the best cross sectional conformal cooling channel, five different types of cross sectional shapes of conformal cooling channels have been designed and analyzed for an industrial plastic part cavity mold. Optimization has been done through transient thermal Finite Element Analysis (FEA) for best temperature distribution in the cavity mold by ANSYS Workbench simulation software. Finally, the mold has been fabricated with square cross sectional conformal cooling channel by the DMD and tested by injection molding of a sample plastic part and compared with conventional straight cooling channel (CSCC) mold. Simulation and experimental results show that SCSCCC shows better temperature distribution in the mold which reduces cycle time of the injection molding process.
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