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Open AccessArticle

A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds

1
School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
2
Mechanical and Energy Engineering Department, Indiana University Purdue University Indianapolis, 723 W Michigan St, Indianapolis, IN 46202, USA
*
Author to whom correspondence should be addressed.
Appl. Sci. 2018, 8(12), 2567; https://doi.org/10.3390/app8122567
Received: 1 November 2018 / Revised: 4 December 2018 / Accepted: 7 December 2018 / Published: 11 December 2018
(This article belongs to the Special Issue 3D Printing of Metals)
Plastic injection molding is a versatile process, and a major part of the present plastic manufacturing industry. The traditional die design is limited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermomechanical) performance. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum conformal channels based on thermomechanical performance are not found in the literature. This paper proposes a design methodology to generate optimized design configurations of such channels in plastic injection molds. The design of experiments (DOEs) technique is used to study the effect of the critical design parameters of conformal channels, as well as their cross-section geometries. In addition, designs for the “best” thermomechanical performance are identified. Finally, guidelines for selecting optimum design solutions given the plastic part thickness are provided. View Full-Text
Keywords: additive manufacturing; design of experiments; conformal cooling channels; design and analysis; design rules for additive manufacturing additive manufacturing; design of experiments; conformal cooling channels; design and analysis; design rules for additive manufacturing
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MDPI and ACS Style

Jahan, S.A.; El-Mounayri, H. A Thermomechanical Analysis of Conformal Cooling Channels in 3D Printed Plastic Injection Molds. Appl. Sci. 2018, 8, 2567.

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