Abstract
A conformal cooling channel (CCC) is widely employed in the injection mold due to uniform cooling. The cooling efficiency of the epoxy resin mold (ERM) strictly depends on the thermal conductivity since the cooling time directly affects the productivity. According to the practice experience, the material cost of commercial aluminum (Al)-filled epoxy resin is high and the cooling efficiency of the injection mold fabricated by commercial materials is limited to the physical properties. Accordingly, developing an injection mold with high cooling efficiency at low cost is therefore of critical importance. This study develops a low-cost recipe for making injection molds. It was found that both the cooling efficiency and material cost are better than those made with commercial Al-filled epoxy resin. The difference in the cooling time of the injection molded parts between the simulation and experiment is approximately 22%. The remarkable findings of this study are very practical and provide good application prospects in the investment casting industry.
Similar content being viewed by others
Data and material availability
Data openly available in a public repository that issues datasets with DOIs
References
Zhao Y, Mattner T, Drummer D (2019) Investigation of the effects of pre-cross-linked thermoset molding compounds on weld line strength in injection molding. Int J Adv Manuf Technol 105:1723–1733
Tran NT, Englich S, Gehde M (2018) Visualization of wall slip during thermoset phenolic resin injection molding. Int J Adv Manuf Technol 95:4023–4029
Kanbur BB, Suping S, Duan F (2020) Design and optimization of conformal cooling channels for injection molding: a review. Int J Adv Manuf Technol 106:3253–3271
Reggiani B, Todaro I (2019) Investigation on the design of a novel selective laser melted insert for extrusion dies with conformal cooling channels. Int J Adv Manuf Technol 104(1–4):815–830
Ming W, Chen Z, Du J et al (2020) A comprehensive review of theory and technology of glass molding process. Int J Adv Manuf Technol 107:2671–2706. https://doi.org/10.1007/s00170-020-05051-0
Liu C, Cai Z, Dai Y, Huang N, Xu F, Lao C (2018) Experimental comparison of the flow rate and cooling performance of internal cooling channels fabricated via selective laser melting and conventional drilling process. Int J Adv Manuf Technol 96(5–8):2757–2767
Li Z, Wang X, Gu J, Ruan S, Shen C, Lyu Y, Zhao Y (2018) Topology optimization for the design of conformal cooling system in thin-wall injection molding based on BEM. Int J Adv Manuf Technol 94(1–4):1041–1059
Kitayama S, Miyakawa H, Takano M, Aiba S (2017) Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel. Int J Adv Manuf Technol 88(5–8):1735–1744
Wang X, Li Z, Gu J, Ruan S, Shen C, Wang X (2016) Reducing service stress of the injection-molded polycarbonate window by optimizing mold construction and product structure. Int J Adv Manuf Technol 86(5–8):1691–1704
Brooks H, Brigden K (2016) Design of conformal cooling layers with self-supporting lattices for additively manufactured tooling. Addit Manuf 11:16–22
Chen J, Gong P, Liu Y, Zheng X, Ren F (2017) Optimization of hot stamping cooling system using segmented model. Int J Adv Manuf Technol 93(1–4):1357–1365
Singraur DS, Patil BT, Rampariya Y (2019) Advancements in design and fabrication of conformal cooling channels for improvement in plastic injection molding process. Ind Eng J 12(5):1–6
Mercado-Colmenero JM, Martin-Doñate C, Rodriguez-Santiago M, Moral-Pulido F, Rubio-Paramio MA (2019) A new conformal cooling lattice design procedure for injection molding applications based on expert algorithms. Int J Adv Manuf Technol 102(5–8):1719–1746
Abbès B, Abbès F, Abdessalam H, Upganlawar A (2019) Finite element cooling simulations of conformal cooling hybrid injection molding tools manufactured by selective laser melting. Int J Adv Manuf Technol 103(5–8):2515–2522
Kalami H, Urbanic RJ (2019) Design and fabrication of a low-volume, high-temperature injection mould leveraging a ‘rapid tooling’ approach. Int J Adv Manuf Technol 105:3797–3813
Rajaguru J, Duke M, Au C (2015) Development of rapid tooling by rapid prototyping technology and electroless nickel plating for low-volume production of plastic parts. Int J Adv Manuf Technol 78(1–4):31–40
Wu H, Lu B, Guo C, Wei R (2015) Structural analysis on the arc spraying rapid tooling for sheet forming. Int J Adv Manuf Technol 77(9–12):2277–2287
Meng F, Zhang H, Wang G (2014) Experiment research on green machining of clay prototype for plasma spray tooling. Int J Adv Manuf Technol 70(5–8):1415–1419
Hsu FH, Wang K, Huang CT, Chang RY (2013) Investigation on conformal cooling system design in injection molding. Adv Prod Eng Manag 8(2):107–115
Kuo C, Jiang Z, Yang X et al (2020) Characterization of a direct metal printed injection mold with different conformal cooling channels. Int J Adv Manuf Technol 107:1223–1238
Kuo C, Jiang Z (2019) Numerical and experimental investigations of a conformally cooled maraging steel injection molding tool fabricated by direct metal printing. Int J Adv Manuf Technol 104:4169–4181
Kuo C, Jiang Z, Lee J (2019) Effects of cooling time of molded parts on rapid injection molds with different layouts and surface roughness of conformal cooling channels. Int J Adv Manuf Technol 103:2169–2182
Jahan SA, Wu T, Zhang Y, el-Mounayri H, Tovar A, Zhang J, Acheson D, Nalim R, Guo X, Lee WH (2016) Implementation of conformal cooling & topology optimization in 3D printed stainless steel porous structure injection molds. Procedia Manuf 5:901–915
Wang Y, Yu KM, Wang CCL, Zhang Y (2011) Automatic design of conformal cooling circuits for rapid tooling. Comput Aided Des 43:1001–1010
Au KM, Yu KM (2013) Conformal cooling channel design and CAE simulation for rapid blow mould. Int J Adv Manuf Technol 66:311–324
Kuo C, Chen W, Lin Y et al (2020) Effects of different fillers on the silicone rubber mold with conformal cooling channels. Int J Adv Manuf Technol 108:1509–1525
Barbosa EL, Santos Delfino ACd, Brandão LC (2017) The use of alternative coolant techniques to reduce the environmental impact in the use of water in through-feed centreless grinding. Int J Adv Manuf Technol 91:3417–3425
Guiza G, Larcher A, Goetz A, Billon L, Meliga P, Hachem E (2020) Anisotropic boundary layer mesh generation for reliable 3D unsteady RANS simulations. Finite Elem Anal Des 170:103345–103351
Kitayama S, Hashimoto S, Takano M, Yamazaki Y, Kubo Y, Aiba S (2020) Multi-objective optimization for minimizing weldline and cycle time using variable injection velocity and variable pressure profile in plastic injection molding. Int J Adv Manuf Technol 107:3351–3361
Ojo-kupoluyi OJ, Tahir SM, Dele-Afolabi TT, Anuar MS (2020) Controlling the sintering response in the development of multilayered components produced via powder injection molding route—a review. Int J Adv Manuf Technol 107:3755–3777
Dong Y, Yan W, Wu Z, Zhang S, Liao T, You Y (2020) Modeling of shrinkage characteristics during investment casting for typical structures of hollow turbine blades. Int J Adv Manuf Technol 110:1249–1260. https://doi.org/10.1007/s00170-020-05861-2
Huang P, Shih LK, Lin H et al (2019) Novel approach to investment casting of heat-resistant steel turbine blades for aircraft engines. Int J Adv Manuf Technol 104:2911–2923. https://doi.org/10.1007/s00170-019-04178-z
Jiang RS, Zhang DH, Bu K, Wang WH, Tian JW (2017) A deformation compensation method for wax pattern die of turbine blade. Int J Adv Manuf Technol 88(9–12):3195–3203
Cui K, Wang W, Jiang R, Zhao D (2018) Layout optimization method for core holders in wax pattern mold of hollow turbine blade. Int J Adv Manuf Technol 98(1–4):1031–1045
Lan X, Li C, Yang L, Xue C (2018) Deformation analysis and improvement method of the Ni-P mold core in the injection molding process. Int J Adv Manuf Technol 99:2659–2668
Park H, Rhee B (2016) Effects of the viscosity and thermal property of fluids on the residual wall thickness and concentricity of the hollow products in fluid-assisted injection molding. Int J Adv Manuf Technol 86:3255–3265
Lu L, Han J, Fan C, Xia L (2018) A predictive feedrate schedule method for sculpture surface machining and corresponding B-spline-based irredundant PVT commands generating method. Int J Adv Manuf Technol 98:1763–1782
Kitayama S, Yamazaki Y, Takano M, Aiba S (June 2018) Numerical and experimental investigation of process parameters optimization in plastic injection molding using multi-criteria decision making. Simul Model Pract Theory 85:95–105
Prapamonthon P, Yin B, Yang G, Zhang M (2019, 100505) Understanding of temperature and cooling effectiveness sensitivity of a film-cooled vane under coolant inlet temperature effect: a case study. Case Stud Therm Eng 14
Vashisht R, Kapila A (2014) A comparative study of coolants based on the cooling time of injection molding. Int J Emerg Technol Adv Eng 4(6):830–834
Wei H, Hussain G, Iqbal A, Zhang ZP (2019) Surface roughness as the function of friction indicator and an important parameters-combination having controlling influence on the roughness: recent results in incremental forming. Int J Adv Manuf Technol 101:2533–2545
Makki MM, Ahmed B, Chokri B (2018) Reliability prediction of the stress concentration factor using response surface method. Int J Adv Manuf Technol 94:817–826
Jin SY, Pramanik A, Basak AK, Prakash C, Shankar S, Debnath S (2020) Burr formation and its treatments—a review. Int J Adv Manuf Technol 107:2189–2210. https://doi.org/10.1007/s00170-020-05203-2
Munhoz MR, Dias LG, Breganon R, Ribeiro FSF, de Souza Gonçalves JF, Hashimoto EM, da Silva Júnior CE (2020) Analysis of the surface roughness obtained by the abrasive flow machining process using an abrasive paste with oiticica oil. Int J Adv Manuf Technol 106:5061–5070
Dong G, Marleau-Finley J, Zhao YF (2019) Investigation of electrochemical post-processing procedure for Ti-6Al-4V lattice structure manufactured by direct metal laser sintering (DMLS). Int J Adv Manuf Technol 104:3401–3417
Tyagi P, Goulet T, Riso C, Garcia-Moreno F (2019) Reducing surface roughness by chemical polishing of additively manufactured 3D printed 316 stainless steel components. Int J Adv Manuf Technol 100:2895–2900
Yung KC, Zhang SS, Duan L, Choy HS, Cai ZX (2019) Laser polishing of additive manufactured tool steel components using pulsed or continuous-wave lasers. Int J Adv Manuf Technol 105:425–440
Nagalingam AP, Yeo SH (2018) Effects of ambient pressure and fluid temperature in ultrasonic cavitation machining. Int J Adv Manuf Technol 98:2883–2894
Zhou M, Kong L, Xie L, Fu T, Jiang G, Feng Q (2017) Design and optimization of non-circular mortar nozzles using finite volume method and Taguchi method. Int J Adv Manuf Technol 90(9–12):3543–3553
Chen WC, Nguyen MH, Chiu WH, Chen TN, Tai PH (2016) Optimization of the plastic injection molding process using the Taguchi method, RSM, and hybrid GA-PSO. Int J Adv Manuf Technol 83(9–12):1873–1886
Adnan MF, AbdullahE AB, Samad Z (2017) Springback behavior of AA6061 with non-uniform thickness section using Taguchi Method. Int J Adv Manuf Technol 89(5–8):2041–2052
Pinar AM, Filiz S, Ünlü BS (2016) A comparison of cooling methods in the pocket milling of AA5083-H36 alloy via Taguchi method. Int J Adv Manuf Technol 83(9–12):1431–1440
Gong G, Chen JC, Guo G (2017) Enhancing tensile strength of injection molded fiber reinforced composites using the Taguchi-based six sigma approach. Int J Adv Manuf Technol 91(9–12):3385–3393
Altaf K, Rani AMA, Raghavan VR (2013) Prototype production and experimentalanalysis for circular and profiled conformalcooling channels in aluminium filledepoxy injection mould tools. Rapid Prototyp J 19(4):220–229
Hasan M, Zhao J, Huang Z, Wei D, Jiang Z (2019) Analysis and characterisation of WC-10Co and AISI 4340 steel bimetal composite produced by powder–solid diffusion bonding. Int J Adv Manuf Technol 103(9–12):3247–3263
Ling Z, Wu J, Wang X, Li X, Zheng C (2019) Experimental study on the variance of mechanical properties of polyamide 6 during multi-layer sintering process in selective laser sintering. Int J Adv Manuf Technol 101(5–8):1227–1234
Yan A, Wang Z, Yang T, Wang Y, Ma Z (2017) Sintering densification behaviors and microstructural evolvement of W-Cu-Ni composite fabricated by selective laser sintering. Int J Adv Manuf Technol 90(1–4):657–666
Yamamoto S, Azuma H, Suzuki S, Kajino S, Sato N, Okane T, Nakano S, Shimizu T (2019) Melting and solidification behavior of Ti-6Al-4 V powder during selective laser melting. Int J Adv Manuf Technol 103(9–12):4433–4442
Liu Y, Yang Y, Wang D (2016) A study on the residual stress during selective laser melting (SLM) of metallic powder. Int J Adv Manuf Technol 87(1–4):647–656
Wei D, Anniyaer A, Koizumi Y, Aoyagi K, Chiba A (2019) On microstructural homogenization and mechanical properties optimization of biomedical Co-Cr-Mo alloy additively manufactured by using electron beam melting. Addit Manuf 28:215–227
Le TN, Lo YL, Tran HC (2019) Multi-scale modeling of selective electron beam melting of Ti6Al4V titanium alloy. Int J Adv Manuf Technol 105:545–563
Scharowsky T, Bauerei A, Körner C (2017) Influence of the hatching strategy on consolidation during selective electron beam melting of Ti-6Al-4V. Int J Adv Manuf Technol 92(5–8):2809–2818
Riedlbauer D, Scharowsky T, Singer RF, Steinmann P, Körner C, Mergheim J (2017) Macroscopic simulation and experimental measurement of melt pool characteristics in selective electron beam melting of Ti-6Al-4V. Int J Adv Manuf Technol 88(5–8):1309–1317
Liang W, Kang X, Zhao W, Yang Y (2016) Electrical discharge machining of electron beam melting formed shrouded blisk. Int J Adv Manuf Technol 87(5–8):2319–2326
Pobel CR, Reichel S, Fu Z, Osmanlic F, Körner C (2019) Advanced process strategy to realize microducts free of powder using selective electron beam melting. Int J Adv Manuf Technol 103(1–4):1291–1296
Ameen W, Al-Ahmari A, Mohammed MK (2019) Self-supporting overhang structures produced by additive manufacturing through electron beam melting. Int J Adv Manuf Technol 104:2215–2232
Hossain MS, Mireles J, Morton P, Lin Y, Terrazas CA, Wicker RB (2018) Part re-registration during process interruption of electron beam melting additive manufacturing. Int J Adv Manuf Technol 96(1–4):337–344
Al-Tamimi AA, Huang B, Vyas C, Hernandez M, Peach C, Bartolo P (2019) Topology optimised metallic bone plates produced by electron beam melting: a mechanical and biological study. Int J Adv Manuf Technol 104:195–210
Laouissi A, Yallese MA, Belbah A, Belhadi S, Haddad A (2019) Investigation, modeling, and optimization of cutting parameters in turning of gray cast iron using coated and uncoated silicon nitride ceramic tools. Based on ANN, RSM, and GA optimization. Int J Adv Manuf Technol 101(1–4):523–548
Wojtewicz M, Nadolny K, Kapłonek W, Rokosz K, Matýsek D, Ungureanu M (2019) Experimental studies using minimum quantity cooling (MQC) with molybdenum disulfide and graphite-based microfluids in grinding of Inconel alloy 718. Int J Adv Manuf Technol 101(1–4):637–661
Yang M, Li C, Zhang Y, Jia D, Li R, Hou Y, Cao H (2019) Effect of friction coefficient on chip thickness models in ductile-regime grinding of zirconia ceramics. Int J Adv Manuf Technol 102(5–8):2617–2632
Guo G, Kethineni C (2020) Direct injection molding of hybrid polypropylene/wood-fiber composites reinforced with glass fiber and carbon fiber. Int J Adv Manuf Technol 106:201–209
Huang Y, Liu S, Xiao G, He Y, Wang W (2020) Experimental investigation into the effects of adhesion wear on belt grinding of glass fiber reinforced plastics. Int J Adv Manuf Technol 109:463–473
Tang Z, Huang X, Wang C, Liao B, Lin D, Yao J, Zheng L (2020) Micro-drilling characteristics of sequential glass fiber-reinforced resin-based/copper foil multi-layer sheets. Int J Adv Manuf Technol 107:399–410
Ounaies M, Harchay M, Dammak F, Daly HB (2019) Numerical simulation of humidity diffusion through the polyester/glass fiber composite. Int J Adv Manuf Technol 105:4237–4243
Ginestra PS, Ceretti E (2020) Stress-induced stabilization of pyrolyzed polyacrylonitrile and carbon nanotubes electrospun fibers. Int J Adv Manuf Technol 108:117–127
Park KM, Kurniawan R, Yu Z, Ko TJ (2019) Evaluation of a hybrid cryogenic deburring method to remove uncut fibers on carbon fiber-reinforced plastic composites. Int J Adv Manuf Technol 101:1509–1523
Barbosa LCM, Gomes G, Junior ACA (2019) Prediction of temperature-frequency-dependent mechanical properties of composites based on thermoplastic liquid resin reinforced with carbon fibers using artificial neural networks. Int J Adv Manuf Technol 105:2543–2556
Chen J, An Q, Ming W, Chen M (2020) Investigation on machined surface quality in ultrasonic-assisted grinding of Cf/SiC composites based on fracture mechanism of carbon fibers. Int J Adv Manuf Technol 109:1583–1599
Lucas A, Danlos A, Shirinbayan M, Motaharinejad V, Paridaens R, Benfriha K, Bakir F, Tcharkhtchi A (2019) Conventional rotational molding process and aerodynamic characteristics of an axial-flow hollow blades rotor. Int J Adv Manuf Technol 104:1183–1194
Redaelli DF, Abbate V, Storm FA, Ronca A, Sorrentino A, de Capitani C, Biffi E, Ambrosio L, Colombo G, Fraschini P (2020) 3D printing orthopedic scoliosis braces: a test comparing FDM with thermoforming. Int J Adv Manuf Technol 111:1707–1720
Aaboud B, Saouab A, Park CH (2019) Modeling of air bubble dynamics during resin transfer molding by pore doublet model. Int J Adv Manuf Technol 105:2343–2355
Cortina M, Arrizubieta JI, Calleja A, Ukar E, Alberdi A (2018) Case study to illustrate the potential of conformal cooling channels for hot stamping dies manufactured using hybrid process of laser metal deposition (LMD) and milling. Metals 8(102):1–15
Krebelj K, Halilovič M, Mole N (2019) The cooling rate dependence of the specific volume in amorphous plastic injection molding. Int J Adv Manuf Technol 103(1–4):1175–1184
Li A, Lan Q, Dong D, Liu Z, Li Z, Bian Y (2014) Integrated design and process analysis of a blow molding turbo-charged pipe. Int J Adv Manuf Technol 73(1–4):63–72
Safarian A, Subaşi M, Karataş Ç (2017) The effect of sintering parameters on diffusion bonding of 316 L stainless steel in inserted metal injection molding. Int J Adv Manuf Technol 89(5–8):2165–2173
Funding
This study received financial support from the Ministry of Science and Technology of Taiwan under contract nos. MOST 109-2637-E-131-004, MOST 107-2221-E-131-018, MOST 106-2221-E-131-010, MOST 106-2221-E-131-011, and MOST 105-2221-E-131-012.
Author information
Authors and Affiliations
Contributions
Chil-Chyuan Kuo: wrote the paper, conceived and designed the analysis, and performed the analysis; Jia-Qi Wu: collected the data and contributed data or analysis tools
Corresponding author
Ethics declarations
Ethics approval
This manuscript has not been submitted to more than one journal for simultaneous consideration. The submitted work is original and has not been published elsewhere in any form or language (partially or in full) and is not a part of a single study that has been split up into several parts to increase the quantity of submissions and submitted to various journals or to one journal over time (i.e., “salami-slicing/publishing”). Results have been presented clearly, honestly, and without fabrication, falsification, or inappropriate data manipulation (including image-based manipulation). The authors have adhered to discipline-specific rules for acquiring, selecting, and processing data. No data, text, or theories by others are presented as if they were the authors’ own (“plagiarism”). Proper acknowledgements to other works have been given (these include material that is closely copied (near verbatim), summarized, and/or paraphrased), and quotation marks (to indicate words taken from another source) have been used for verbatim copying of material, and permissions secured for material that is copyrighted.
Consent to participate
I understand that all information I provide for this study will be treated confidentially.
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Kuo, CC., Wu, JQ. Development of a low-cost epoxy resin mold with high cooling efficiency. Int J Adv Manuf Technol 113, 2065–2086 (2021). https://doi.org/10.1007/s00170-021-06716-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06716-0