GANDHINAGAR INSTITUTE OF TECHNOLOGY

EVALUATION OF CONFORMAL COOLING CHANNEL DESIGN IN DIRECT METAL LASER SINTERING FOR RAPID TOOLING

PREPARED BY-VARUN C. VYAS (120120119191)MALAVYA A. SHROTRIYA (120120119063)DHRUMIL B. PATEL (120120119048)

GUIDED BY- PROF. HIMANSHU K. BAROT ASSISTANT PROFESSOR,

MECHANICAL ENGINEERING DEPARTMENT, GANDHINAGAR INSTITUTE OF

TECHNOLOGY

PROJECT OUTLINEABSTRACTINTRODUCTIONMARKET RESEARCH/SURVEYFEASIBILITY AND APPLICATIONWORKING PRINCIPLEDESIGNCONFORMAL VS CONVENTIONAL DESIGN FUTURE SCOPE OF WORK

THE AIM OF THIS RESEARCH PAPER IS TO DESIGN TWO VARIANTS OF COOLING SYSTEMS (CAVITIES) FOR AN INJECTIONMOULD. BOTH SYSTEMS ARE DESIGNED TO BE USED ON THE SAME INJECTION MOULD FOR PRODUCING THE SAME PRODUCT. THEDIFFERENCE IS IN THE MANUFACTURING TECHNOLOGY ITSELF.

ABSTRACT

INTRODUCTION

The present manufacturing method is material removal by cutting technology which consumes more raw material, tooling cost, more sequence of operations with consideration of rework and rejection.

The market demand is to put new product first in the market at a very reasonable rate. New product is the assembly of many parts.

Then question comes how to reduce time and development cost ???

By using the techniques of layer by layer manufacturing using Direct Metal Laser Sintering we reduce the time of manufacturing and using conformal cooling concept we can get better quality of the product.

Project Features

To study the process of rapid tooling machine and redesign the conformal cooling channel. Our project is consist of different types of rapid prototype method used in the industries.

With the design of the conformal cooling channel we can obtain better quality of prototypes and can create complex materials in time.

Future scope :-

The alternative material will also be invented to reduce the cost by conformal cooling channel design method.

The evaluation of the design can also be done by changing the design of the channel for another part.

The layer thickness further then 0.35um in the range of 20-80 um can also be change as one parameter to evaluate the tool performance.

Analysis of Various Parameters (Conventional Method)

Time

The melt front time varies from minimum 0 at the bottom side to maximum 0.5 second from the top side.

Melt Front time for packing is from 0.002 sec to 0.501 sec.

The total cooling time taken as 0.000 to 12.3 sec maximum.

AIR TRAP

The figure shows the various air traps arise duringthe process. Fillingand packing air trap is same as per analysis.

DENSITY

The packing Density varies from 1.03g/cc to 1.101 g/cc at various Sections.

TEMPERATURE

The Filling Temperature varies from 78.3*C to 233.723*C at different segments

The Package temperature varies from 55.4*C to 225*C at the different Segments.

Mesh type eDesign3No. of cooling channel

1

Part dimension 74.00 x 62.04 x 62.04 (mm)Mold dimension 116.00 x 196.00 x 196.00 (mm)Cavity vol. 15.752 (cc)Element no. 685681Part element 685681Node number 427300

Analysis by Conventional Method

PROCESS CONDITIONMelt temp. ( normal) 225*CMelt temp. (max.) 250*CMelt temp. ( min.) 200*CMold temp. ( min.) 20*CMold temp. ( max ) 90*CMold temp. ( normal ) 55*CEjection temp. 100*C

Comparison:-

Conventional Cooling Method Simple construction.

Steel pipes are used for cooling channels.

Outcome of the final product is not appropriate.

Conformal Cooling Channel Complex construction.

Copper pipe is used for cooling channels.

Outcome of the final product is of good quality as compare to the conventional cooling method.

2) PRACTICAL DATA BY CONVENTIONAL METHOD

1) INJECTION MOLDING PROCESS.

2) DATA BY PRACTICAL METHOD.

3) PRACTICAL DATA BY CONFORMAL CHANNEL

1) TECHNICAL DATA.

2) MACHINE. - MACHINE MAIN COMPONENTS. - MACHINE EXTERNAL COMPONENTS. - MACHINE SAFETY. - VARIOUS DMLS MATERIALS. - MATERIAL CHARACTERSTICS.

3) MATERIAL PROPERTIES.

MATERIAL SELECTION

MATERIAL TYPE:- Solid. Thermoplastic material such as ABS and PC-ABC. Aluminium and stainless steel.

MAXIMUM MATERIAL PART SIZE:- 355.6 mm.

APPLICATION:- Functional testing, Rapid tooling patterns, Small detailed parts, Presentation models, High heat applications.

4) CONCLUSION.

CYCLE TIME (sec.) CONVENTIONAL CONFORMAL COOLING

virtual 21.5 6.5Practical 15 7

By performing this experiment on conventional and conformal cooling methods we found the better design is conformal cooling channel which reduces the cycle time with improved quality standard.

It also shows the effect of both designs and productivity as the cycle time is reduced so productivity is increased.

Cooling channel cross sections can take almost any shape. A more effective mould temperature control system saves time and costs in the

process of injection moulding process. The cost of the conformal cooling insert is high due to high cost of material.

5) FUTURE SCOPE

The evaluation of the design can also be done by changing the design of the channel for another part.

The layer thickness can also be changed. The tool material as an alternative of CL50 can also be checked.

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