Design of Conformal Cooling Channels Using Numerical Methods in a Metal Mold and Calculating Exergy Destruction in Channels

Abstract

Shorter cycle times, better product quality and less product outage can be possible with faster cooling. But mold cooling channels can only be made in linear directions and limited forms via classical manufacturing methods. Therefore, it limits that performance of mold cooling. Developed in recent years additive manufacturing technologies are capable of building complex geometries and monoblock 3D products. With this technology it is possible to produce metal molds with conformal cooling channels in different forms and capable of qualified cooling. In this study, conformal cooling channels were designed in order to achieve optimum cooling in monoblock permanent mold. In this study, CFD (Computational Fluid Dynamic) analyses are performed to steady stead conditions for designed conformal cooling channels and classical cooling channel mold. Pressure drops, cooling channel outlet temperatures and exergy destructions are calculated depending on the flow velocity rate in channels. The numerical investigations of the cooling process have shown that approximately 5% higher cooling performance can be achieved with conformal cooling channels. However, the pressure drop in the conformal cooling is observed to be higher than classical cooling channel. In addition, exergy destruction in the conformal cooling channel is approximately 12% greater than the classical cooling channel.