Application of new conformal cooling layouts to the green injection molding of complex slender polymeric parts with high dimensional specifications

TL;DR

This paper introduces an innovative conformal cooling system with additively manufactured channels and steel inserts to significantly reduce warpage, cycle time, and residual stresses in complex slender injection-molded polymer parts, enhancing sustainability and manufacturing quality.

Contribution

It presents a novel green conformal cooling layout combined with steel inserts for complex slender geometries, demonstrating substantial improvements over traditional cooling methods.

Findings

Cycle time reduced by 66% (175.1 s)

Warpage decreased by 90.5% (6.9 mm)

Residual stress lowered by 81.88% (39.78 MPa)

Abstract

Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric features, and this occurs with topologies of great length and slenderness with high changes in thickness. These features are, in these special geometries, impossible to manufacture with traditional technologies to meet the dimensional and sustainable requirements of the industry. This paper presents an innovative green conformal cooling system that is specifically designed for parts with slender geometric shapes that are highly susceptible to warping. Additionally, the work presented by the authors investigates the importance of using highly conductive inserts made of steel alloys in combination with the use of additively manufactured conformal channels for reducing influential parameters, such as warpage, cooling time, and residual stresses in the complex manufacturing of long and slender parts. The results of this real industrial case study indicated that the use of conformal cooling layouts decreased the cycle time by 175.1 s 66% below the current cooling time; the temperature gradient by 78.5% specifically, 18.16 C; the residual stress by 39.78 MPa or 81.88%; and the warpage by 6.9 mm or 90.5%. In this way, it was possible to achieve a final warping in the complex geometry studied of 0.72 mm, which was under the maximum value required at the industrial level of 1 mm. The resulting values obtained by the researchers present a turning point from which the manufacturing and sustainability in the injection molding of said plastic geometries is possible, and they take into account that the geometric manufacturing features analyzed will present a great demand in the coming years in the auto parts manufacturing industry.