Conformal Cooling PPT

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Introduction
What and Why is Conformal Cooling?
Conformal Cooling Process
Conformal Cooling Design and Manufacturing
Application Industries
Mold Heat Transfer
Benefits of Conformal Cooling
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What is Conformal Cooling?
Conformal cooling is the process of using coolant
channels in plastic injection mold tools which
closely follow, or conform, to the shape of the
part being molded. They differ from standard
cooling channels in that they are not confined to
the line-of-sight, straight holes that are
created from conventional drilling or milling.
Conformal cooling channels follow the twists and
turns of complex part designs, and so offer much
better cooling efficiency and faster cycle times.
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Why is Conformal Cooling?
Because its an industry game changer.
Conventional molds have straight-line cooling
channels. Simply put, conformal cooling makes use
of cooling lines in an injection mold that curve
and closely follow the geometry of the part to be
produced. There are a variety of methods for
manufacturing a conformally cooled mold,
including laser sintering, vacuum brazing, liquid
interface diffusion, and others.
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Conformal Cooling Process
Part Selection
The first step is to select an injection molding
plastic part and evaluate fill time and pack time
on FEA software package.
Analysis
Now analyze cooling time, volumetric shrinkage
and deflection with traditionally designed
cooling channel.
Designing
The next step is to design the conformal cooling
channel by referring to the data given by
previous analysis.
Printing
In the final step, analyze cooling time,
volumetric shrinkage and deflection with the
conformal cooling channel. Compare results and
print the mould insert as per the result gained
from the analysis.
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Conformal Cooling Design and Manufacturing
The advent of additive manufacturing has given
engineers across industry new and exciting ways
of designing and manufacturing components and
finished parts.   
In the field of injection moulding, the additive
manufacturing process has given us the ability to
develop a new generation of tooling that offers
considerable scope to improve the quality of
finished mouldings, while improving
cycle time and productivity. 
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Application Industries
Plastic Injection Molding
Cooling system improvement is an emerging area of
research in plastic injection molding. The
injection molding process is cyclic in
characteristic. Filling, packing, cooling, and
ejection are the steps of the injection molding
process. Among the number of stages involved in
injection molding of plastics, the cooling stage
is a very important stage as it affects the
productivity and mold quality.
Pressure Die Casting
Conformal Cooling Channel in die casting
application improves the surface finish of
castings due to a reduced need for spray cooling,
which is allowed by a higher and more uniform
cooling rate. Other benefits include reduction of
cycle time and shrinkage porosity.
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Mold Heat Transfer
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
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Benefits of Conformal Cooling
There are several benefits of using additive
manufacturing for conformal cooling such as
improved product quality, energy savings, scrap
reduction, productivity and overall efficiency.
Using Additive Manufacturing for conformal
cooling is more effective when the production
volume is large and the parts have complex
geometry. When using 3D printing, an excellent
surface finish can be acquired, cycle time can be
reduced drastically as much as 70 in some cases,
and production costs can be lowered
significantly. There are various other benefits,
which are as follows
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Benefits of Conformal Cooling
Improved dimensional stability of parts.
Minimum warpage and shrinkage of parts.
Increased production by up to 50
Improved surface finish quality of plastic parts.
Minimum thermal gradient throughout the part
while cooling.
Significant reduction in part rejection.
Reduced resources required for the production
such as labor, the number of machines, space and
energy.
Faster delivery time.
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Conventional cooling VS Conformal cooling
Conventional cooling
Conformal cooling 
The distance from cavity to cooling channel
differs due to limitations of conventional
machining process. As a result, the heat
dissipation cannot take place uniformly in the
material
Cooling channels are placed uniformly and close
to the profile of the part
Uniform cooling results in improved part quality
Uneven cooling results in internal stresses that
negatively impact part quality (warpage)
The production cycle time is reduced because of
faster cooling
Design driven manufacturing results in maximum
freedom of design
Cooling time is longer since cooling channels
cannot reach all intricate areas
Highly productive tools and faster pay-back
Improved profits !
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CONTACT US
WWW.innovae3d.com
sales_at_innovae3d.com
7666900439
Plot No. PAP-V-137, Phase-2, MIDC Chakan, Vasuli
Village, Khed TalukPune District 410 501, India
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