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Conf Cooling-Ind App PDF
Conf Cooling-Ind App PDF
Moldex3D R11
European
Webinar
Series
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
Mold Close
Screw moves forward
Filling Stage
Packing Stage
66
Advanced Injection Molding Processes
> Goals:
Shorten cycle time
Material saving
Quality improvement
77
Cooling channel design
88
Introduction of Conformal Cooling
99
Introduction of Conformal Cooling
1010
Introduction of Conformal Cooling
From http:\\\www.3dinnovation.dk/conformal_cooling_eng.htm
1111
What are the benefits of conformal
cooling?
1212
Mold Heat Transfer
The importance of heat dissipation
1414
Cooling system components
1515
Mold Heat Transfer
1616
Heat Conduction and Convection
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
2020
Conformal Cooling Manufacturing
Matsuura
LUMEX
①Powder Supply
Repeat 10
times
②Laser Sintering
10 times
③Milling
Repeat
2222
Vacuum Brazing
2323
CAE Analysis on Conformal
Cooling
Moldex3D Solution for Conformal
Cooling
2525
Moldex3D Solution for Conformal
Cooling – eDesign procedures
Step 1: import part and runner Step 4: generate mesh
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
2727
Moldex3D Solution for Conformal
Cooling
2828
Moldex3D Solution for Conformal
Cooling
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
3131
Cooling Channel Design
Conventional Conformal
3232
Cooling Analysis – Cooling
Temperature
Conventional Cooling Conformal Cooling
3333
Cooling Analysis – Cooling Time
Conventional Cooling Conformal Cooling
3434
Cooling Analysis – Cooling
Efficiency
Conventional Cooling Conformal Cooling
Cooling Efficiency
3535
Cooling Analysis – Mold Temp
Difference
Conventional Cooling Conformal Cooling
3636
Cooling Analysis -- Mould
Temperature
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%.
Displacement comparison
3838
Result Summary
> From the photo of actual product, we can also see the
warpage improvement is significant in z direction.
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 ℃
Temperature range:
79~105 ℃
Temperature range:
75~98 ℃
Temperature range:
79~98 ℃
EOC Moldbase
temperature:79~84 ℃
4545
Temperature history at sensor nodes
4848
Thank you for your attention!
Contact Information
Dr. Hsu
andrewhsu@moldex3d.com
Larry
larryren@moldex3d.com
5050