Research On Thermal Response Of Mould Conformal Cooling Structure Effect On Non-uniform Thick-wall Product Precision Forming

Research on conformal cooling structure impacts on the thermal response of products forming. Commonly, Traditional mold cooling structure is linear straight pipes, the cooling effect is not so well. To optimize the drawback, we put forward a new cooling structure design named conformal cooling, compare the traditional linear structure with conformal cooling via the transient thermal analysis in ANSYS program, then get the results of cooling efficiency and cavity temperature field distribution of the two schemes, take advantage of Moldflow and CFD software to analyze the temperature distribution along with the injection molding products molded under conformal cooling and the potential shortcomings. Take examples of projector case and car navigation base which is heterogeneous thick-walled product, basing on the structure of the products, deign a conformal grove completely the same with the mold cavity surface structure, the distance between groove surface and cavity wall is constant. Combining heat transfer theory in injection molds, injection molding shrinkage and warpage principles, build production molding models respectively, analyze the temperature field on the surface of the cavity finite element model and the defects of the product molding. Compare and analyze traditional mold cooling and conformal cooling in the following aspects: cavity surface temperature field distribution, product molding period, temperature variation process after mold boot into a steady state, transient temperature variation when the product is finished, volume shrinkage ratio of products, and product warpage due to cooling.It turned out that the cooling effects of conformal cooling is more even ly than traditional one, conformal cooling greatly shorten the product molding cycle, improve the molding quality effectively. For projector case, injection mo lding cycle is shortened by 58.1%, mold cavity surface temperature distribution is more homogeneous, smaller temperature difference, lower overall temperat ure, transient results can quickly adjust the cavity surface temperature better, u ntil the equilibrium state, warpage due to uneven cooling is reduced 38.6%.For car navigation base, heterogeneous thick-walled product, plastic parts moldi ng cycle is shortened 35.3%, mould cavity temperature difference is very small, uniform temperature distribution on the surface of the cavity, plastic parts m olding shrinkage is reduced 10.9%, deformation due to uneven shrinkage is re duced 33.3%.Therefore, conformal cooling design can better improve product q uality, reduce cycle time, and significantly reduces production costs.