Development of Customized Cooling Channels for Molds Using Numerical Simulations and Additive Manufacturing
摘要
Among the various polymer manufacturing methods, the injection molding process stands out, being commonly used for producing highly complex parts in large production batches. However, due to the high production repetition rate and the frequent temperature variations inherent to the process, wear of the mechanical components becomes an intrinsic challenge. Consequently, metallic materials are typically employed in the mechanical assemblies of injection systems. The current demand for parts manufactured through injection molding requires high geometric precision in complex components, combined with the lowest possible cost. Therefore, it is essential to minimize waste, both in the mechanical components of the injection process and in the produced parts. Considering these requirements, two technological tools that contribute to the success of projects in this field are the use of additive manufacturing (AM) in combination with computational numerical simulations. The high thermal gradients involved in the plastic injection molding process, in which specific regions reach higher temperatures than others, often result in distortions in the manufactured parts. Therefore, it is essential to have a cooling system within the molds to promote a more uniform heat exchange and prevent geometric distortions in the produced components. An effective alternative for manufacturing customized cooling channels (conformal cooling) in complex metallic geometries, while ensuring efficient thermal exchange, is the Direct Energy Deposition (DED) process, in which a metallic wire is melted by a laser beam, forming a small molten pool and continuously depositing material layer by layer. In this study, different cooling channel designs are analyzed for a mold component used in the production of automobile cup holders. To enhance cooling efficiency, the channels incorporate complex architected structures known as Triply Periodic Minimal Surfaces (TPMS). The analyses are supported by numerical simulations based on the Computational Fluid Dynamics (CFD) method, aiming to estimate the pressure profile on the mold surface, pressure drop, flow velocity fields, and regions with higher and lower heat transfer rates. The results obtained contribute to a more accurate definition of operational requirements, supporting the selection of the most suitable pump and the optimal process parameters for injection molding.