Search Results (153)

Injection mold design is a repetitive and time-consuming process with common individual tasks related to each other. This study presents the development of an automatic computer-aided design (CAD) tool for basic injection molds with complete modeling and no other interaction by the user after inserting the part, built on the SolidWorks Application Programming Interface 2022 (API) and Visual Basic for Applications 7.1 2012(VBA). The tool combines user input forms and supplier catalog data as inputs in an algorithm to automatically generate mold structures, cavity blocks, runner system, ejection system and straight drilled cooling channels without further manual modeling. Three case studies with one-, two-, and four-cavity molds demonstrate the approach. The results show that complete mold assemblies can be produced in less than 10 min rather than hours while maintaining standard component dimensions. Although the present version applies to rule-based geometric placement rather than thermal or injection process optimization, it provides a framework for future integration of more complex mold structures and functions such as slides, hot runner system, unscrewing geometries, conformal cooling, heat-transfer-based design, family molds and machine selection. This work demonstrates how API-driven automation can reduce design time, standardize layouts, and lay the groundwork for next-generation injection mold development. Full article

Background/Objectives: The All-on-4 technique is a minimally invasive approach for full-arch oral rehabilitation. In cases of anterior bone resorption, the classic All-on-4 configuration may be limited by insufficient bone for axial implant insertion. An effective alternative is the “M” configuration, where all four implants are inserted at approximately 30°. This report presents a clinical case of full-arch rehabilitation using personalized surgical guides with internal cooling, designed to optimize irrigation and prevent thermal bone damage. Methods: A 57-year-old female patient underwent digital planning and flapless guided implant surgery. At the maxilla, four DENTIS SQ implants were inserted in an “M”-shaped configuration (4 × 10 mm anterior, 4 × 14 mm posterior). Before insertion, implant beds were prepared using surgical templates with internal irrigation channels. At the mandible, four posterior implants (4 × 8 mm) were placed using dentally supported guides with internal cooling. The surgical guides were designed using Implastation and Blue Sky Plan, 3D-printed in biocompatible resin and sterilized before use. We performed the osteotomies under controlled irrigation with continuous saline flow through the integrated cooling channels. Results: The guides ensured accurate implant positioning. We did not observe intraoperative complications, and all implants achieved primary stability above 35 N·cm. Postoperative healing was uneventful, with minimal edema and no mucosal dehiscence. These indirect clinical indicators suggest that the guide also ensured effective cooling. Radiographic follow-up confirmed correct 3D positioning and intimate bone-implant contact. Conclusions: This case study shows that personalized surgical guides with integrated coolant channels may provide a safe and precise solution for flapless All-on-4 “M” rehabilitations, reducing thermal risks and enhancing surgical accuracy. Full article

This study establishes a systematic and reproducible workflow for topology optimization (TO) of indexable face milling cutter bodies with integrated internal coolant channels, designed for Additive Manufacturing (AM) of metallic parts. Grounded in Design for Additive Manufacturing (DfAM) principles, the workflow combines displacement-based TO and computational fluid dynamics analysis to generate simulation-driven tool geometries tailored to the constraints of AM. By leveraging iterative design knowledge, the proposed methodology enhances the scalability and repeatability of the design process, reducing development time and supporting rapid adaptation across various tool geometries. AM is explicitly exploited to integrate support-free internal coolant channels directed toward the insert cutting edge, thereby achieving a 20% mass reduction relative to the initial milling tool designs, and improving material usage efficiency at the design stage. The workflow yields numerically optimized geometries that maintain simulated global stiffness under the considered loading conditions and exhibit coolant flow distributions that effectively target the exposed cutting edges. These simulation results demonstrate the feasibility of an AM oriented, workflow-based approach for the numerical design of milling tools with internal cooling, mass reduction and provide a focused basis for subsequent experimental validation and comparison with conventionally manufactured counterparts. Full article

The invention concerns a screw-driven shredder for solid photopolymer resin, designed for both terrestrial use and prospective deployment in microgravity environments. The system addresses the need for efficient recycling of cured photopolymer waste generated by stereolithography (SLA) 3D printing—a process not yet implemented in orbit, but envisioned as part of future closed-loop additive manufacturing systems aboard space stations or lunar habitats. The proposed device is a compact, hermetically sealed mechanical unit composed of ten subassemblies, featuring two counter-rotating screw shafts equipped with carbide milling inserts arranged helically to achieve uniform and controlled fragmentation of solid SLA residues. The shredding process is supported by a pressurized inert fluid circuit, utilizing carbon dioxide (CO₂) as a cryogenic working medium to enhance cutting efficiency, reduce heat accumulation, and ensure particle evacuation under microgravity conditions. Studies indicate that CO₂-assisted cooling can reduce tool-tip temperature by 10–30 °C, cutting forces by 5–15%, and electrical power consumption by 5–12% while extending tool life by up to 50%. This invention thus provides a key component for a future in situ photopolymer recycling loop in space while also offering a high-efficiency shredding solution for Earth-based photopolymer waste management in additive manufacturing. Full article

This study introduces Internal Induction Heating (In-IH) as an efficient method for local mold temperature control in thin-walled polypropylene (PP) injection molding. Unlike conventional systems that are slow and energy-intensive, the insert is integrated directly into the induction circuit in the In-IH system, generating eddy currents for rapid and localized heating. Numerical and experimental analyses were performed to examine the effects of insert geometry and heating parameters; it was found that thinner inserts achieved higher surface temperatures—the 0.5 mm insert reached ~550 °C, while the 2.0 mm insert reached only ~80 °C—confirming an inverse relationship between thickness and temperature. Narrower inserts (25 mm) concentrated heat more effectively, whereas wider ones yielded better temperature uniformity. The cooling conditions strongly affected the temperature gradients. Mold-filling experiments demonstrated that In-IH significantly improved the flowability of PP: at 180 °C, the 0.4 mm specimen achieved a flow length of 85.33 mm, compared with 43.66 mm for the 0.2 mm specimen. At 250–300 °C, all samples approached full filling (~100 mm). The simulation and experimental results agreed, with a maximum deviation of 10%, confirming that In-IH provides rapid, energy-efficient, and precise temperature control, thus enhancing melt flow and product quality for thin-walled PP components. Full article

This study focuses on the design and optimization of a cooling layer system integrated into a thin-thickness mold insert to enhance heat transfer efficiency, control mold temperature, and improve the quality of composite products during injection molding. The Taguchi method with an L25 (5⁴) orthogonal array was employed to investigate four key parameters: insert thickness, cooling layer thickness, water flow rate, and coolant temperature. Among 25 experimental combinations, five representative cases were selected for detailed analysis. The results indicate that the optimal configuration (0.5 mm insert, 10 mm cooling layer, 3.5 L/min flow rate, and 80 °C coolant temperature) successfully maintained a high and stable mold temperature, with a cavity temperature difference of only 3.6 °C at steady state and a simulation–experiment deviation ranging from 2.4% to 7.2%. This condition not only improved melt flowability and surface quality but also reduced defects such as weld lines, warpage, and shrinkage. In parallel, displacement measurements on PA6 and glass fiber-reinforced PA6 (PA6 + GF) composites revealed that increasing the fiber content from 0% to 30% reduced output displacement by more than 19% compared to neat PA6, highlighting the reinforcing effect of glass fibers and the relationship between temperature distribution and mechanical displacement behavior. The findings confirm that integrating a cooling layer into a thin-thickness mold, combined with Taguchi-based optimization, provides an effective approach to enhance through-thickness heat transfer, reduce deformation, and ensure the overall quality of composite injection-molded products in industrial applications. Full article

During transmission line faults, the pre-insertion resistors in circuit breakers accumulate heat and lead to thermal explosion during repeated closing. The risk of thermal explosion can be reduced if the pre-insertion resistor temperature can be accurately predicted. This study proposes a method for predicting the pre-insertion resistor temperature to optimize the cooling time. The overfitting problem is more serious for models using traditional loss functions. To solve this problem, deep learning models based on a new loss function, the rational smoothing loss, are used to predict the temperature of pre-insertion resistors. The rational smoothing loss, inspired by the kernel function, dynamically adjusts the error versus gradient and incorporates constraints for regularization. The coati optimization algorithm with Ornstein–Uhlenbeck mutation optimizes the rational smoothing loss parameters. The results demonstrate that models using rational smoothing loss significantly outperform those with traditional loss functions, showing reductions of 77.97% in mean absolute error and 93.72% in mean square error, reducing the mean absolute error to 0.29 K. Additionally, the prediction curves exhibit remarkable smoothness, indicating the rational smoothing loss’s robustness against overfitting. The accurate prediction of pre-insertion resistor temperature is crucial for safely operating circuit breakers and technically supporting cooling time optimization. Full article

Additive manufacturing offers significant design freedom for injection mold tooling, particularly in optimizing cooling performance and reducing mass. This study presents a holistic framework for the topology optimization of mold inserts considering design for additive manufacturing principles, integrating essential boundary conditions from the mold making, injection molding process, and post-processing operations. A slider component with conformal cooling channels serves as the case study. Using simulation-driven design and finite element analysis, two design variants, based on conventional and modified design spaces, were evaluated. Mechanical loads from clamping and the injection process were considered, with safety factors applied to reflect industrial misuse scenarios. The topology optimization process was implemented using Altair OptiStruct and validated through displacement and stress analyses. The results show savings in both mass and costs of up to 60% while maintaining structural integrity under operational and misuse conditions. The maximum displacements—only a 4 µm increase compared to the reference—remained within DIN ISO 20457 tolerances, and stresses did not exceed 170 MPa under operational conditions, confirming industrial applicability. This study concludes with a proposed framework for integrating topology optimization into mold design workflows. Full article

The paper explores the application of heat pipes in thermal management for efficient heat dissipation, particularly in electrical equipment with high heat loads. Heat pipes are devices that transfer heat with high efficiency through the phase transition of the working medium (e.g., water, alcohol, ammonia) between the evaporator and the condenser, while they have no moving parts and are distinguished by their simplicity of construction. Different types of heat pipes—gravity, capillary, and closed loop (thermosiphon loop)—are suitable according to specific applications and requirements for the working position, temperature range, and condensate return transport. An example of an effective application is the removal of heat from the internal winding of a static energy converter transformer, where the use of a gravity heat pipe has enabled effective cooling even through epoxy insulation and kept the winding temperature below 80 °C. Other applications include the cooling of mounting plates, power transistors, and airtight cooling of electrical enclosures with the ability to dissipate lost thermal power in the order of 102 to 103 W. A significant advantage of heat pipes is also the ability to dust-tightly seal equipment and prevent the build-up of dirt, thereby increasing the reliability of the electronics. In the field of environmental technology, systems have been designed to reduce the radiant power of fireplace inserts by up to 40%, or to divert their heat output of up to about 3 kW into hot water storage tanks, thus optimising the use of the heat produced and preventing overheating of the living space. The use of nanoparticles in the working substances (e.g., Al₂O₃ in water) makes it possible to intensify the boiling process and thus increase the heat transfer intensity by up to 30% compared to pure water. The results of the presented research confirm the versatility and high efficiency of the use of heat pipes for modern cooling requirements in electronics and environmental engineering. Full article

Effective thermal management of molds is a governing factor of the quality and stability of the injection molding process. This study introduces and validates an integrated cooling layer within a thin-walled insert mold designed to enhance thermal control and cavity filling performance. A coupled heat transfer simulation model was developed and subsequently calibrated against experimental temperature measurements. To isolate the mold’s intrinsic thermal response, temperatures were measured during distinct heating and cooling cycles, free from the perturbations of polymer melt flow. The validated mold was then installed on a Haitian MA1200 III injection molding machine to conduct molding trials under various injection pressures. A strong correlation was found between the simulation and experimental results, particularly as pressure increased, which significantly improved cavity filling and reduced the deviation between the two methods. The integrated cooling layer was shown to enhance heat dissipation, minimize thermal gradients, and promote a more uniform thermal field. This, in turn, improved filling stability, especially at moderate injection pressures. These findings provide robust quantitative data for simulation model calibration and mold design optimization, highlighting the potential of advanced cooling strategies to significantly enhance injection molding performance. Full article

HTRI xchanger Suite 6.0 software was employed to analyze the thermodynamic performance and thermal resistance distribution of the fuel/lubricating oil heat exchanger A for an aeroengine. Calculated results demonstrated good agreement with experimental results for both heat transfer and flow resistance characteristics. The thermal resistance analysis revealed that the tube-side contribution dominated, accounting for 84.6% of the total resistance. The whole aeroengine test revealed that insufficient tube-side velocity resulted in prolonged fuel filling time, subsequently delaying fuel ignition and affecting aeroengine starting. To address these issues while maintaining lubricating oil cooling requirements, a structural optimization incorporating twisted tape inserts was proposed. It was calculated by HTRI software that when the twist ratio and the thickness of twisted tape inserts was 4 and 0.5 mm, respectively, the optimized fuel/lubricating oil heat exchanger B demonstrated remarkable performance improvements, with an 82.6% reduction in total thermal resistance, a 213% increase in overall heat transfer coefficient, and an 18.0% reduction in total mass. A subsequent whole aeroengine test at the performance evaluation point confirmed that heat exchanger B successfully met all technical requirements of total mass, flow resistance, heat transfer rate, and aeroengine starting, simultaneously. The demonstrated methodology presents significant potential for broader aerospace thermal management applications, such as performance prediction of enhanced heat exchangers, multi-objective optimization of thermal systems, and integrated thermal management solutions. Full article

This study evaluates the application of metal additive manufacturing—specifically the laser powder bed fusion (LPBF) process—for producing aluminium die-casting mould components, comparing 300-grade maraging steel inserts with conventional H13 tool steel. Efficient thermal management and mould durability are critical in aluminium injection moulding. Still, traditional machining limits the design of cooling channels, resulting in hot spots, accelerated wear, and a reduced service life. LPBF allows the fabrication of complex geometries, enabling conformal cooling channels to enhance thermal control. Component samples were manufactured using maraging steel via LPBF, machined to final dimensions, and subjected to duplex surface treatment (plasma nitriding + CrAlN PVD coating). Thermal performance, dimensional stability, mechanical properties, and wear resistance were experimentally assessed under conditions simulating industrial production. The results demonstrate that LPBF components with optimised cooling channels and surface engineering achieve higher thermal efficiency, an extended service life (up to 2.6×), improved hardness profiles (545 HV0.05 core, 1230 HV0.05 on nitrided surface and 2850 HV0.05 after PVD film deposition), and reduced maintenance frequencies compared to H13 inserts. The study confirms that additive manufacturing, combined with tailored surface treatments and optimised cooling design, overcomes the geometric and thermal limitations of conventional manufacturing, offering a reliable and productive solution for aluminium die-casting moulds. Full article

Practical applications such as solar power energy systems, electronic cooling, and the convective drying of vented enclosures require continuous developments to enhance fluid and heat flow. Numerous studies have investigated the enhancement of heat transfer in L-formed vented cavities by inserting heat-generating components, filling the cavity with nanofluids, providing an inner rotating cylinder and a phase-change packed system, etc. Contemporary work has examined the thermal performance of L-shaped porous vented enclosures, which can be augmented by using metal foam, using nanofluids as a saturated fluid, and increasing the wall surface area by corrugating the cavity’s heating wall. These features are not discussed in published articles, and their exploration can be considered a novelty point in this work. In this study, a vented cavity was occupied by a copper metal foam with $PPI=10$ and saturated with a copper–water nanofluid. The cavity walls were well insulated except for the left wall, which was kept at a hot isothermal temperature and was either non-corrugated or corrugated with rectangular waves. The Darcy–Brinkman–Forchheimer model and local thermal non-equilibrium models were adopted in momentum and energy-governing equations and solved numerically by utilizing commercial software. The influences of various effective parameters, including the Reynolds number ($20\le Re\le 1000$), the nanoparticle volume fraction ($0\%\le \phi \le 20\%$), the inflow and outflow vent aspect ratios ($0.1\le D/H\le 0.4$), the rectangular wave corrugation number ($N=5$ and $N=10$), and the corrugation dimension ratio ($CR=1$ and $CR=0.5$) were determined. The results indicate that the flow field and heat transfer were affected mainly by variations in $Re$, $D/H$, and $\phi$ for a non-corrugated left wall; they were additionally influenced by $N$ and $CR$ when the wall was corrugated. The fluid- and solid-phase temperatures of the metal foam increased with an increase in $Re$ and $D/H$. The fluid-phase Nusselt number near the hot left sidewall increased with an increase in $\phi$ by $\left(25–60\right)\%$, while the solid-phase Nusselt number decreased by $\left(10–30\right)\%$, and these numbers rose by around $3.5$ times when the Reynolds number increased from $20$ to $1000$. For the corrugated hot wall, the Nusselt numbers of the two metal foam phases increased with an increase in $Re$ and decreased with an increase in $D/H$, $CR$, or $N$ by $10\%$, $19\%$, and $37\%$. The original aspect of this study is its use of a thermal, non-equilibrium, nanofluid-saturated metal foam in a corrugated L-shaped vented cavity. We aimed to investigate the thermal performance of this system in order to reinforce the viability of applying this material in thermal engineering systems. Full article

Etching has become a critical step in semiconductor wafer fabrication, and its importance in semiconductor manufacturing highlights the fact that it directly determines the ability of the fab to produce high-process products, as well as the application performance of the chip. While the health of the etcher is a concern, especially for the cooling system, accurately predicting the remaining useful life (RUL) of the etcher cooling system is a critical task. Predictive maintenance (PDM) can be used to monitor the basic condition of the equipment by learning from historical data, and it can help solve the task of RUL prediction. In this paper, we propose the FECAM-WTCN-Informer model, which first obtains a new WTCN structure by inserting wavelet convolution into the TCN, and then combines the discrete cosine transform (DCT) and channel attention mechanism into the temporal neural network (TCN). Multidimensional feature extraction of time series data can be realized, and the processed features are input into the Informer network for prediction. Experimental results show that the method is significantly more accurate in terms of overall prediction performance (MSE, RMSE, and MAE), compared with other state-of-the-art methods, and is suitable for solving the problem of predictive maintenance of etching machine cooling systems. Full article

The efficient thermal management of cutting tools is critical for ensuring dimensional accuracy, surface integrity, and tool longevity, especially in the high-speed dry machining process. However, conventional cooling methods often fall short in reaching the heat-intensive zones near the cutting inserts. This study proposes a novel internal cooling strategy that integrates triply periodic minimal surface (TPMS) structures into the toolholder, aiming to enhance localized heat removal from the cutting region. The thermal-fluidic behaviors of four TPMS topologies (Gyroid, Diamond, I-WP, and Fischer–Koch S) were systematically analyzed under varying coolant velocities using computational fluid dynamics (CFD). Several key performance indicators, including the convective heat transfer coefficient, Nusselt number, friction factor, and thermal resistance, were evaluated. The Diamond and Gyroid structures exhibited the most favorable balance between heat transfer enhancement and pressure loss. The experimental validation confirmed the CFD prediction accuracy. The results establish a new design paradigm for integrating TPMS structures into toolholders, offering a promising solution for efficient, compact, and sustainable cooling in advanced cutting applications. Full article