4.5 Article

Prototype production and experimental analysis for circular and profiled conformal cooling channels in aluminium filled epoxy injection mould tools

Journal

RAPID PROTOTYPING JOURNAL
Volume 19, Issue 4, Pages 220-229

Publisher

EMERALD GROUP PUBLISHING LTD
DOI: 10.1108/13552541311323236

Keywords

Injection moulding; Aluminium-filled epoxy; Thermal management; Conformal cooling channels; Profiled cooling channels; Thermal efficiency; Cooling systems

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Purpose - The purpose of this paper is to present a technique of fabricating profiled conformal cooling channels (PCCC) in an aluminium filled epoxy mould using rapid prototyping (RP) and rapid tooling (RI) techniques and to compare the cooling times for the moulds with circular and profiled channels experimentally. The cooling channels in injection mould tools have a circular cross section. In a PCCC, the cross sectional shape is so designed that the flat face surface of the channel facing the cavity follows the profile of the cavity. These types of channels can be manufactured through RP and RI techniques. Design/methodology/approach - A part to be moulded was designed and modelled. Two moulds were then designed with the part cavity, one having a circular channel and the second with a profiled channel, both having the same cross sectional area for coolant flow. The channel patterns were designed with supports according to their position regarding height and distance from the cavity as designed earlier. Both channels have the same distance from the cavity wall. RP patterns were produced for both channels and part using the Thermojet 3D printer. The cooling channel and the moulded part patterns were then assembled as designed in the moulds. Moulding frames were fabricated with aluminium plates and the pattern was placed in the frames. Epoxy was poured on the pattern and then cured. The moulded part and the channel patterns embedded inside epoxy were melted out during the final curing cycle, leaving behind the circular- and profiled-cooling channels in the moulds. For the cooling time measurement, injection moulding was done with moulds with circular and profiled channels. Moulded part temperature will be recorded by embedding thermocouples within the mould cavities. Findings - A technique for the manufacture of cooling channels of different profiles in epoxy moulds was presented. Experimental analysis for temperature measurement for the moulded part with injection moulding process showed that PCCC mould has less cooling time then mould with circular channels. Research limitations/implications - The technique presented is based on the metal-filled epoxy materials used in RI and was obtained using a specific test part. Epoxy tooling can be a useful alternative of metallic mould to produce injection mould tools. A limitation for the epoxy moulds is that they have a limited life as compared with metallic moulds. Originality/value - This is a new technique of manufacturing moulds with cooling channels using RP/RT techniques. Moulds with different channel cross sections can be manufactured using this technique.

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