2012

Moldex3D R11
European
Webinar
Series

Conformal Cooling Industrial Application

and Design Optimization Technology
Definition

Con-for-mal adj.
1. :Leaving the size of the angle between corresponding curves
unchanged
2. of a map: representing small areas in their true shape

Origin:
Late Latin conformalis having the same shape, from Latin
Com- + formalis formal, from forma
First known use: 1893

Source:/www.merriam-webster.com/dictionary
22
Dr. Andrew Hsu

» Current position:
CoreTech System senior engineer
» Education:
Ph.D. of Mechanical engineering
in University of California, Davis
» Research area:
Aerodynamics, heat transfer, numerical analysis,
advanced injection molding process (conformal
cooling, GAIM/WAIM
Dr. Hsu joined CoreTech System (Taiwan) in 2010. His recent research is focus on CAE
and several advanced injection molding fields such as gas/water assisted injection mold,
injection compression molding, optical parts, and conformal cooling.
Dr. Hsu has several years teaching experience in professional fields such as heat
transfer and injection molding. He have assisted several famous injection molding
manufacturers to solve real industry cases worldwide. His teaching combines theories
and practical cases which offers a thorough understanding for those from novice to
experienced professionals in injection molding field.
33
Contents

> Introduction
– What and why is conformal cooling
– Benefits
> Mold Heat Transfer
– Conduction, Convection, Radiation
> Conformal Cooling Design and Manufacturing
– Design
– Manufacturing: laser sintering and vacuum brazing
> CAE Analysis on Conformal Cooling
> Case Study
– Carriage model
– Cup model
> Summary

44
Introduction
 Injection Molding Procedures

Cooling Stage Mold open/Ejection

Mold Close
Screw moves forward

Filling Stage

Packing Stage

Nozzle shut off

Screw moves backward

66
 Advanced Injection Molding Processes

> Goals:
Shorten cycle time
Material saving
Quality improvement

Gas/Water assisted injection molding

- Weight reduction(~40%), improve product
quality, reduce cooling time
Conformal Cooling
- Reduce cooling time (20-60%)
- Improve product quality
Variotherm
- Improve product quality

77
Cooling channel design

Q:What’s the best design for these products?

88
 Introduction of Conformal Cooling

> What is conformal cooling?

– Cooling channel design based on product contour.

> Why is conformal cooling?

– To increase cooling efficiency. With conformal cooling, cooling rate
difference can be minimized through the whole part.
– To reduce cycle time and cost
– To have better product quality

Source: EOS whitepaper, Siegfried Mayer (EOS GmbH)

99
 Introduction of Conformal Cooling

> When to use conformal cooling?

– For products with complex geometry. In order to remove heat from
areas where traditional tooling method can not reach.

> How to manufacture conformal cooling channels?

– DMLS (Direct Metal Laser-Sintering) and vacuum brazing methods
are usually applied. Traditional drilling method may have problems
in manufacturing conformal cooling system.

1010
Introduction of Conformal Cooling

> Some examples

From http:\\\www.3dinnovation.dk/conformal_cooling_eng.htm

1111
What are the benefits of conformal
cooling?

> Problems on polymer molding

– Sink mark
– Warpage
– Cycle time

> Use conformal cooling during the injection molding

process to:
– Improve product quality such as warpage and sink
mark
– Decrease cycle time

1212
Mold Heat Transfer
The importance of heat dissipation

1414
Cooling system components

> Contains components like:

– Mold Temperature Controller
– Regular Channel
– Manifold
– Hose
Insulated
– Others：Baffle or Bubbler

1515
Mold Heat Transfer

> Heat Transfer Modes:

– Conduction
– Convection
– Radiation
> Heat Transfer Considered in Injection Molding:
– Heat removed from cavity to mold base
– Heat removed from mold base to cooling channels
– Mold surface radiation
– Mold surface convection
– Heat removed at ejection

1616
Heat Conduction and Convection

> Cooling system design and cooling time:

• Heat Conduction between cavity and cooling channels (Fourier’s Law):

 
dq dT
q 
"
 k T  k 
Adt dx
c
• Heat convection equation
inside cooling channels:


dq
q 
"
 hT  h(T 4  T 3)
Adt
• Coolant Type
Cavity
• Coolant velocity
• Cooling channel diameter b
• Coolant temperature b
h: conv. heat transfer coefficient Cooling Mold base
Channel 1717
Conformal Cooling Design and
Manufacturing
 Cooling Channel Design Parameters

• Three parameters on cooling channel design:

Distance between pipe and cavity: c
Distance between pipes: a
Pipe diameter: b

Theoretically, c should be as smaller as possible. And the values of a and b are

dependant. However, mold strength and lifecycle is a great concern.

So, there is a experimental design guideline for the three parameters as shown in the
table.
Source: EOS whitepaper, Siegfried Mayer (EOS GmbH)

1919
 Conformal Cooling Channel Design

Source: EOS whitepaper, Siegfried Mayer (EOS GmbH)

2020
Conformal Cooling Manufacturing

Matsuura

Direct Metal Laser Sintering Machine

LUMEX Avance-25
2121
Conformal Cooling Manufacturing

LUMEX

①Powder Supply

Repeat 10
times
②Laser Sintering

10 times

③Milling
Repeat

2222
Vacuum Brazing

> Brazing is a metal-joining process whereby a filler

metal is heated above and distributed between two or
more close-fitting parts by capillary action.
> The filler metal is brought slightly above its melting
(liquidus) temperature while protected by a suitable
atmosphere, usually a flux. It then flows over the base
metal (known as wetting) and is then cooled to join
the workpieces together. It is similar to soldering,
except the temperatures used to melt the filler metal
are above 450 °C (842 °F).
> Vacuum brazing is a materials joining technique that
offers significant advantages: extremely clean,
superior, flux-free braze joints of high integrity and
strength.
Source: http://en.Wikipedia.org

2323
CAE Analysis on Conformal
Cooling
Moldex3D Solution for Conformal
Cooling

> For any complex cooling channel design. Meshing can be

constructed in Moldex3D with ease.
> STL format files can be imported and defined as cooling
channel or heating rod in Designer.

2525
 Moldex3D Solution for Conformal
Cooling – eDesign procedures
Step 1: import part and runner Step 4: generate mesh

Step 2: import .stl cooling channel

Step 3: define attribute as “cooling channel”

Step 5: export file for simulation

2626
 Moldex3D Solution for Conformal
Cooling – Solid procedures
Step 1: import part and runner model in Rhino Step 4: construct BLM/hybrid solid mesh
for cooling channels

Step 2: build runner/cavity solid mesh

Step 3: import cooling channel file

Step 5: build mold base solid mesh

Step 6: export solid model

2727
Moldex3D Solution for Conformal
Cooling

> Cooling time and transient mold temperature can be

estimated. The right figure shows the temperature
animation.

2828
Moldex3D Solution for Conformal
Cooling

> The flow properties (temperature, pressure, velocity) inside

the cooling channels can be estimated in 3D.

R11 Solid only

2929
Moldex3D Solution for Conformal
Cooling

Moldex3D can:
 Predict required coolant flow rate to fit production cycle
time
 Predict possible pressure loss in your cooling channel
design
 Prevent vortex/dead water area in your cooling channel
design
 Simulate baffle/bubbler designs in a true 3D approach

3030
1. Carriage Model

> As shown in the figure below, the hallow interior of this

part is the crucial area. With traditional cooling channel
design, this is mostly the area with heat accumulation.
This will cause inward warp during injection molding
process.

3131
Cooling Channel Design

> The conventional design has no cooling channel inside

the hallow interior. With conformal cooling design, warp
can be reduced.

Conventional Conformal

3232
Cooling Analysis – Cooling
Temperature
Conventional Cooling Conformal Cooling

Cooling Temperature Cooling Temperature

60.650 ~ 114.647 ℃ 60.388 ~ 69.126 ℃

3333
Cooling Analysis – Cooling Time
Conventional Cooling Conformal Cooling

Cooling Time Cooling Time

3434
Cooling Analysis – Cooling
Efficiency
Conventional Cooling Conformal Cooling

Cooling Efficiency

3535
Cooling Analysis – Mold Temp
Difference
Conventional Cooling Conformal Cooling

Mold Temp Difference

Mold Temp Difference

3636
Cooling Analysis -- Mould
Temperature

> The two figures below show the mould temperature

distribution of conventional and conformal cooling
design. We can see the maximum temperature drops
from 114.7 ℃ to 69.2 ℃

Conventional Cooling Conformal Cooling

3737
Result Summary

> For this case, the z-direction warp is the most concerned
point. Compare the conventional cooling system design
with conformal design, z-direction warp reduced by 87%.

Conventional Conformal Improved

(%)
X -0.2512 ~ -0.2585 ~ -3
0.2439 mm 0.2499 mm
Y -0.113 ~ 0.133 -0.098 ~ 11
mm 0.12mm
Z -0.677 ~ 0.655 -0.084 ~ 87
mm 0.086 mm
Total 0.001 ~ 0.685 0.001 ~ 61
mm 0.265mm

Displacement comparison
3838
Result Summary

> From the photo of actual product, we can also see the
warpage improvement is significant in z direction.

Conventional Cooling Conformal Cooling

3939
2. Cup Model

•Length： 90 mm

•Width： 90 mm

•Height：120 mm

•Thickness： 2 mm

4040
 Product temperature -- Baffle
Temperature
animation

Temperature range：
75~103 ℃

EOC product surface

temperature: 82~91 ℃
4141
Moldbase temperature -- Baffle
Temperature animation

Temperature range：
79~105 ℃

EOC mold temperature

range:79~91 ℃
4242
Temperature history at sensor nodes

Cooling rates at each node are not the

same, this will affect product quality. EOC
product surface temperature is 84~91 ℃,
temperature difference is 5~7 ℃.

Flow Pack Cool Open

4343
 Product temperature -- Conformal
Temperature
animation

Temperature range：
75~98 ℃

EOC product surface

temperature range: 80~82 ℃
4444
Moldbase temperature -- Conformal
Temperature animation

Temperature range：
79~98 ℃

EOC Moldbase
temperature:79~84 ℃
4545
Temperature history at sensor nodes

Cooling rates at each node are closer

than traditional cooling. EOC product
surface temperature is 80.5~81.5 ℃,
temperature difference is 2~3 ℃ .

Flow Pack Cool Open

4646
Summary
Summary

> Conformal cooling is an effective way to shorten cycle

time and improve product quality at the same time.
– In carriage model:
• warpage in z direction improve 87%
• cooling time shorten 61%.
– In cup model:
• cycle time reduction up to 42%
> Moldex3D can predict:
– Transient mold/part temperature
– Coolant physical properties
– Cooling time and efficiency
which is a useful tool for conformal cooling design validation.

4848
Thank you for your attention!
Contact Information

Dr. Hsu
andrewhsu@moldex3d.com

Larry
larryren@moldex3d.com

5050