Development of green conformal cooling channels for rapid tooling
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ORIGINAL ARTICLE
Development of green conformal cooling channels for rapid tooling Chil-Chyuan Kuo 1,2
&
Zheng-Yan You 1 & Seng-Jie Chang 1 & Jie-Dui Liao 1 & Shao-Ting Yu 1 & Rong-Ting Zeng 1
Received: 5 July 2020 / Accepted: 16 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The production cost is related to productivity greatly in the mass production. To enhance productivity, the rapid tooling (RT) with conformal cooling channel (CCC) is widely used for small-volume production in the current industry. In this study, green CCC for RT was developed. This study proposes four methods to move polyvinyl butyral (PVB) CCC. It was found that flushing with alcohol is the best way of removing PVB CCC. The use of alcohol to remove PVB CCC has three advantages, including less volatile, environmentally friendly, and harmless to the operator compared with conventional method using acetone. The removing mechanism of PVB CCC embedded in the RT was demonstrated. The removal rate of the PVB CCC is not linear. The wax feedstock filaments with better toughness were developed for fabricating CCC. The optimum process parameters for fabricating wax filament include barrel temperature of 44 °C, height of extrusion of 80 cm, and screw speed of 6 rpm. The temperature of removing wax CCC embedded in RT is only about 85 °C, which is very low compared with commercially available wax filament. Keywords Rapid tooling . Polyvinyl butyral . Conformal cooling channel . Wax filament
1 Introduction The injection molding (IM) [1] is one of the most largevolume production approaches. In general, the IM process [2–5] involves four fundamental stages such as filling, packing, cooling, and ejection stages. Increasing the productivity is a very important issue for mass production in the machinery industry by shortening the cycle time (CT). In general, the CT can be shortened by the mold [6] or die [7] with conformal cooling channel (CCC) since the CCC possesses the potential to enhance the cooling performance of the mold or die in terms of uniform cooling during the cooling stage. Abbes et al. [8] revealed an injection molding tool with CCC to increase productivity. The results of this study clearly showed the cooling of injection mold inserts can be improved significantly through hybrid CCC. Kitayama et al. [9] investigated the
* Chil-Chyuan Kuo [email protected] 1
Department of Mechanical Engineering, Ming Chi University of Technology, New Taipei City, Taiwan
2
Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
process parameters of plastic injection molding to reduce warpage of the plastics products using CCCs. This work confirmed that the CCCs provide the reduction on the warpage of the injection molded part. Brooks and Brigden [10] presented a concept for designing the conformal cooling layers with selfsupporting lattices. Results revealed that the cooling time of the injection molded part can be reduced about 2
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