pps proceeding - Abstract Preview
pps proceeding
Symposium: S04 - Injection molding
Oral Presentation
 
 

Comparison of additive and conventional manufactured injection molding inserts

Mitterlehner Thomas (1)*, Steinbichler Georg (1)

(1) Johannes Kepler University Linz - Linz - Austria

The cooling time in injection molding can constitute up to 70% of the cycle time. With the additive manufacturing technology there is a new method for designing and optimizing cooling channels available. With this method it is possible to manufacture conformal cooling channels randomly orientated inside injection molds. This enables the possibility of designing more efficient cooling and more even heat dissipations which results in a reduction of thermal stresses and higher accuracies of injection molding parts. In this context several cooling channel designs which only can be manufactured with additive manufactured technologies were construed. To optimize the flow behavior of the coolant, simulations with the open source CFD program OpenFoamŪ were done. To verify the simulation results, an experimental tool was manufactured. Moreover the injection mold is designed in a way that both a conventional and an additive manufactured insert can be operated simultaneously. In this context one part of the injection mold was manufactured with the selective laser melting technology from the material 1.2709. The second part of the mold was manufactured conventional by milling from the material 1.2083. This opens the possibility to compare both manufacturing technologies at the same time. After the additive and the conventional inserts of the mold are manufactured several injection molding parts were produced. The heat distribution on the cavity surface was evaluated with thermographic measurement methods. The main goal is to obtain precise statements regarding cycle time, energy consumption, heat distribution and determination of the main effects. Keywords: Additive Manufacturing, Injection Molding, Conformal Cooling