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Mechanics of Additive and Advanced Manufacturing, Volume 9 pp 55–63Cite as

Effect of Porosity on Thermal Performance of Plastic Injection Molds Based on Experimental and Numerically Derived Material Properties

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Abstract

Plastic injection molding industry uses traditionally machined tools and dies to manufacture various sizes and shapes of plastic products. With the advent of advanced manufacturing technology and expanding global competition in business, it is necessary to provide innovative solutions to the injection molding industry to sustain their business. Typically, the cooling time comprises more than half of the overall injection molding cycle time. The application of additive manufacturing technique can provide a solution to reduce the cooling time in injection molding process. The potential of 3D printing technology to produce any size and shape of products using metal powders provides an opportunity to design and produce innovative injection molding tools, which is unattainable by traditional machining process. Though the conformal cooling channels are capable of reducing the cooling time significantly, the cost of manufacturing the injection molds by 3D printing is quite high and hence a crucial decision making factor for the mold designers about whether or not to go for the 3D printed molds. By making the molds porous, it is possible to reduce the cost of additive manufacturing, thus creating a positive impact on the use of 3D printed molds in injection molding business. In this paper, the effect of mold porosity on the thermal performance of the injection molds are studied. The properties of 3D printed mold material and traditional mold material is quite different and have been considered for the analysis. An optimization study has been conducted to identify the best possible design solution in terms of thermal and printing cost perspectives.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Purdue School of Engineering and Technology, Indiana University – Purdue University Indianapolis, 723 West Michigan Street, SL 260, Indianapolis, IN, 46202, USA

    Suchana A. Jahan, Tong Wu, Yi Zhang, Jing Zhang, Andres Tovar & Hazim El-Mounayri

Authors
  1. Suchana A. Jahan
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  2. Tong Wu
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  3. Yi Zhang
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  4. Jing Zhang
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  5. Andres Tovar
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  6. Hazim El-Mounayri
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Corresponding author

Correspondence to Suchana A. Jahan .

Editor information

Editors and Affiliations

  1. Mechanical Engineering, University of Washington, Seattle, Washington, USA

    Junlan Wang

  2. Sandia National Laboratories, Livermore, California, USA

    Bonnie Antoun

  3. Los Alamos National Laboratory, Los Alamos, New Mexico, USA

    Eric Brown

  4. Neil Armstrong Hall, Purdue University, West Lafayette, Indiana, USA

    Weinong Chen

  5. University of Illinois, Urbana-Champaign, Illinois, USA

    Ioannis Chasiotis

  6. United States Naval Academy, Annapolis, Maryland, USA

    Emily Huskins-Retzlaff

  7. Sandia National Laboratories, Albuquerque, New Mexico, USA

    Sharlotte Kramer

  8. Dow Chemical Company, Lake Jackson, Texas, USA

    Piyush R. Thakre

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© 2018 The Society for Experimental Mechanics, Inc.

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Jahan, S.A., Wu, T., Zhang, Y., Zhang, J., Tovar, A., El-Mounayri, H. (2018). Effect of Porosity on Thermal Performance of Plastic Injection Molds Based on Experimental and Numerically Derived Material Properties. In: Wang, J., et al. Mechanics of Additive and Advanced Manufacturing, Volume 9. Conference Proceedings of the Society for Experimental Mechanics Series. Springer, Cham. https://doi.org/10.1007/978-3-319-62834-9_8

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  • DOI: https://doi.org/10.1007/978-3-319-62834-9_8

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-319-62833-2

  • Online ISBN: 978-3-319-62834-9

  • eBook Packages: EngineeringEngineering (R0)

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