Mold Cooling Simulation to Reduce Cycle Times.
Reduce Cycle Times by 20%. ( See stats below )
Mould Cooling simulation allow Imtech to optimize mold and cooling circuit design to achieve uniform part cooling, minimize cycle times, minimise part warpage due to cooling factors, and decrease overall manufacturing costs. ie Increase Profit.
Cooling Channel Design & Optimization
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Example Conformal Cooling Channels
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The new industry buzz is "Conformal Cooling" and the concept is synonymous with new rapid tooling technology. Layered mould construction allows cooling channels to break out of straight line constraints and follow the surface of the mould around corners and over irregular profiles.
Typical savings in the order of 20% on cycle time are not uncommon while also using less cooling water and maintaining more even cavity surface temperature profiles.
A number of well placed cooling channels may have slight increase on the tool manufacture cost, but the payback via a shorter cycle time will result in a phenomenal increase in life time profit. |
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Example Traditional Cooling Channels
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Moldflow MPI/Cool provides tools for modeling mold cooling circuits, inserts, and bases around a part and analyzing the efficiency of the mold's cooling system and helps the tool designer to arrive at an efficient cooling channel layout.
A recent study conducted on a thick wall PP moulding helped reduce the cycle time from 215 seconds to 120 seconds with out any compromise on surface finish. The savings were achieved by adding several baffles/fountains to deep pockets and incorporating high conductivity inserts. Contact us and ask about cycle time reduction. Just a couple of seconds reduction in cycle time can save thousands of dollars in machine time over the product life cycle.
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Traditional Vs Confromal Cooling
Mould material - P20 |
Standard Cooling |
Conformal
Cooling |
Reduction |
Cavity surface temperature –
maximum. |
60.4 Deg C |
29.7 Deg C |
-50% |
Cavity surface temperature – minimum.
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22.5 Deg C |
17.8 Deg C |
-20.8% |
Cavity surface temperature – average.
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36.3 Deg C |
23.9 Deg C |
-34% |
Average cavity surface temperature difference fixed vs moving half.
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16.75 Deg C |
3.6 Deg C |
-460% |
Average water flow rate@ 15 Deg C
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4.5 Litre/m |
2.7 Litre/m |
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Water temperature rise during cycle.
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+1.1 Deg |
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15.2 Sec |
12.17 |
-19.9 % |
Mold Surface Temperature
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Moldflow Cooling analysis calculates the mould surface temperature profile based on the temperature of the in-coming polymer melt, the cycle time and location of cooling channels. The position and number of cooling channels are modified to refine the heat exchange characteristics in for maximum efficiency. |
Cooling Analysis Capability:
Optimize part and mold designs to achieve uniform cooling with the minimum cycle time
View the temperature difference between the core and cavity mold surfaces
Minimize unbalanced cooling and residual stress to reduce or eliminate part warpage
Predict temperature for all surfaces within the mold: part, runners, cooling channels, inserts
Predict the required cooling time for the part and cold runner to determine overall cycle time
- Cavity surface temperature distribution
- Distribution of temperature differences across opposite surfaces of the cavity
- Distribution of average plastic temperature at ejection time
- Distribution of maximum plastic temperature at ejection time
- Relative position of the peak temperature at ejection time
- Distribution of frozen layer thickness
- Temperature profile through thickness for each cavity element |
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- Surface temperature distribution on both sides of inserts and
parting planes
- Distribution of temperature difference across insert and joint line surfaces
- Temperature of mold external surfaces and surface of cooling circuits
- Pressure drop along each cooling circuit
- Variation in coolant temperature through each cooling circuit
- Flow rate in each cooling circuit
- Reynolds number in each cooling circuit
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imtech design has the experience and depth of knowledge to competently help our customers turn more plastic into profit.
Moldflow Plastic Adviser, Moldflow Mpi, Mold flow communicator and Mold Adviser are Mould flow software products for simulating the injection molding of plastic materials. Moldflow is the registered trademark Moldflow Corporation & Moldflow Europe ltd as advised in many trade magazine publications and press releases.
Imtech Design are Moldflow Gold Certified Plastic Flow Simulation Consultants and Engineers.
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