design and simulation of cooling channel for …eprints.utem.edu.my/15586/1/design and simulation of...

lli~~I UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND SIMULATION OF COOLING CHANNEL FOR

PLASTIC INJECTION MOULDING

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor's Degree in Manufacturing Engineering

Technology (Product Design) (Hons.)

by

NURHAFIZA BINTI ZINALASS

B071110224

920131-01-6048

FACULTY OF ENGINEERING TECHNOLOGY

2015

© Universiti Teknikal Malaysia Melaka

tUUf?1~1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: DESIGN AND SIMULATION OF COOLING CHANNELS FOR PLASTIC INJECTION MOULD

SESI PENGAJIAN: 2014/15 Semester 2

Saya NURHAFIZA BINTI ZINALASS

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ¥")

D SULIT

D TERHAD

D TIDAK TERHAD

Alamat Tetap:

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Cop Rasmi:

Simpang 3 Jalan Dato Kayaman Pensyarort Jabotan T elcnologi Kejuruteraan Pembu t n

Fakulti Teknologi Kejurvteraon Universiti T eknikot Malaysia Meloko 02450 Bukit Keteri

Tarikh: ~1../t/~01~ I Perl is

•• Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.


DECLARATION

I hereby, declared this report entitled "Design and Simulation of Cooling Channel

for Plastic Injection Mould" is the results of my own research except as cited in the

references .

Signature

Author' s Name

Date

...... r/J ........................... . NURHAFIZA BINTI ZINALASS

!l..~.' . ~\.>


APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfilment of the requirements for the degree of Bachelor of

Manufacturing Engineering Technology (product design) (Hons.). The member

of the supervisory is as follows:

(Project Supervisor)


ABSTRAK

Projek ini memperkatakan dengan reka bentuk dan simulasi saluran penyejukan

untuk mereka bentuk dua plat acuan bahagian badan pengering rambut dengan

menggunakan perisian CA TIA dan mernindahkan model 3D ke dalam simulasi

perisian Autodesk Mold.flow Insight 2014. Objektif projek ini adalah untuk mereka

bentuk seni bina barn penyejukan saluran dan simulasi dengan menggunakan

Autodesk simulasi Moldflow Insight 2014. Selain daripada itu adalah untuk

membandingkan antara saluran penyejukan lurus konvensional dan seni bina baru

saluran penyejukan. Reka bentuk produk yang akan dianalisis menggunakan

Autodesk simulasi Moldflow Insight 2014 untuk mengurangkan kecacatan yang

muncul semasa proses pengacuan suntikan Selain itu, dalam proses suntikan plastik,

prestasi saluran penyejukan adalah salah satu faktor yang paljng penting kerana ia

mempunyai kesan yang besar ke atas kedua-dua kadar pengeluaran dan kualiti

bahagian plastik. Dalam usaha untuk ·mengurangkan masa kitaran, dan mengawal

taburan seragam suhu, adalah perlu untuk mewujudkan seni bina penyejukan saluran

baru, yang menepati bentuk rongga acuan dan teras. Projek ini membentangkan

kajian simulasi jenis penyejukan saluran dalam suntikan teracu bahagian plastik dan

membandingkan prestasi dari segi masa untuk mencapai suhu pelemparan,

pengecutan isipadu, profil suhu, suhu litar penyejuk dan kecacatan bahagian untuk

menentukan konfigurasi adalah lebih sesuai untuk menyediakan p_enyejukan seragam

dengan masa kitaran minimum. Autodesk simulasi Mold.flow Insight perisian 2014

digunakan untuk memeriksa keputusan prestasi saluran penyejukan


ABSTRACT

This project deals with design and simulation of cooling channel for designing n.vo

plate mould of body hair dryer part by using CA TIA software and transfer the 30

model into Autodesk Moldflow Insight software. The objective of this project is to

design a new architecture of cooling channel and simulate by using Autodesk

simulation Moldflow Insight 2014. Other than that is to compare between

conventional straight cooling channel and the new architecture of the cooling

channel. The design of the product will be analysed using Autodesk simulation

Moldflow Insight 2014 to reduce the defect that appears during the injection

moulding process. Besides, in the injection moulding process, the cooling channel

performance is one of the most crucial factors because it has a significant effect on

both production rate and the quality of the plastic part. In order to reduce the cycle

time, and control the uniform distribution of temperature, it is necessary to create the

new architecture cooling channels, which conform to the shape of the mould cavity

and core. This project presents a simulation study of different types of cooling

channels in an injection moulded plastic part and compares the performance in terms

of time to reach ejection temperature, volumetric shrinkage, temperature profile,

circuit coolant temperature and part defect determine which configuration is more

appropriate to provide uniform cooling with minimum cycle time. Autodesk

simulation Moldflow Insight 2014 software is used to examine the results of the

cooling channel performance.

ii


DEDICATION

The sake of Allah, my Creator and my Master,

My great teacher and messenger, Mohammed (May Allah bless

and grant him), who taught us the purpose of life,

My beloved parents.

For their endless love, support and encouragement.

My supervisor Madam Umi Hayati Ahmad.

And my lecture Mr. Kamal bin Musa

For giving me knowledge and support my project.

My friends who encourage and support me,

AJI the people in my life who touch my heart,

I dedicate this research.


iii

ACKNOWLEDGEMENT

In the Name of Allah, the Most Merciful, the Most Compassionate all praise be to

Allah, the Lord of the worlds and prayers and peace is being upon Mohamed His

servant and messenger.

First and foremost, I have to thank my parents for their love and support throughout

my life. Thanks you both for giving me strength to reach for the stars and chase my

dreams.

I would like to sincerely thank my supervisor, Madam Umi Hayati binti Ahmad, for

her guidance and support throughout this study, and especially for her confidence in

me.

To all my friends, thank you for your understanding and encouraging me during the

whole research in my many moments of crisis. Our friendship makes my life a

wonderful experience. I cannot List all the names here, but you are always on my

mind.

This thesis is only a beginning of my journey. -

Thank you.


iv

Abstrak

Abstract

Dedication

Acknowledgement

Table of Content

List of Tables

List of Figures

TABLE OF CONTENT

List Abbreviations, Symbols and Nomenclatures

CHAPTER 1: INTRODUCTION

1.1 Project Background

I . I. I . Plastic Inj ection Moulding

I . l .2. 2 Plate Mould

1.1.3. Cooling Channel

1.1.3. I Straight Cooling Channel

1.1.3.2 The New Architecture Cooling Channel

l. I .4 Project Briefing

1.2 Problem Statement

1.3 Objective

1.4 Scope


II

Ill

IV

v-v

v

v - v

v

1

1

1 - 3

4

5- 6

6

7

7

8

8

9

v

CHAPTER 2: LITERATURE REVIEW 10

2.1 Plastic Injection Moulding 10 - 11

2.1.1 Plastic Material 12

2.1.2 Characteristics Of Plastic Material 12 - 13

2.1.2.1 Thermoplastic 13 - 16

2.2 Injection Process 16

2.2.1 Injection Moulding Cycle 17

2.2.1.1 Injection And Filling Stage 18

2.2.1.2 Cooling Or Freezing Stage 18

2.2.1.3 Ejection And Resetting Stage 18

2.3 Mould Design 19

2.3.1 Classification Of Mould 19

2.3.2 Two Plate Mould 19

2.4 Cooling Channel System 20 - 21

2.4.1 Straight Cooling Channel 22 - 23

2.4.2 New Architecture Cooling Channel 24

2.4.3 Comparison Cooling Channel 25

2.5 Autodesk Mouldflow Insight 26

2.6 Moulding Defects 27

2.6.1 Flow Marks And Ripples 28

2.6.2 Weld Lines And Meld Line 29

2.6.3 Air Trap 30

CHAPTER3:METHODOLOGY 31-32

3.1 Create 3D Model 33 - 34

3.2 Import Model To Autodesk Simulation Moldflow Insight 35

3.3 Mesh The Model 36-38

3.4 Setting Up An Analysis 39

3.4.1 Material Selection 40

3.4.2 Setting Parameters 41- 42

vi


3.5 Gate And Runner Placement

3.6 Cooling Analysis

3.7 Modelling Cooling Component

3.7.1 Straight Cooling Channel

3.7.2 The New Architecture Cooling Channel

3.8 Run Cooling Analysis (Fill + Pack + Cool + Warp)

3.9 Cooling Optimized

3.10 Cooling Result Interpretation

3.11 Mould Defect

CHAPTER 4: RESULT AND DISCUSSION

4.1 Analysis, Plastic Material

4.2 Setting Parameters

4.3 Modelling Cooling Component

4.4 Cooling Result Interpretation

4.4.1 Time To Reach Ejection Temperature

4.4.2 Time To Reach Ejection Temperature, Part

4.4.3 Average Volumetric Shrinkage

4.4.4 Circuit Coolant Temperature

4.4.5 Circuit Reynold Number

4.4.6 Mould Temperature

4.5 Mould Defect

4.5.1 Warpage

4.5.2 Weld Lines

4.5.3 Air Traps Defects

4.6 Discussion

CHAPTER 5: CONCLUSION AND FUTURE WORK83

5.1

5.2

5.3

Conclusion

Suggestion For The Future Work

Project Potential

REFERENCE


42 - 44

45

45

46

47

48

49

49 - 50

51

52

52 -60

61

62 - 63

64

65 - 66

67 - 68

69- 70

71 - 72

73 - 74

75 - 76

77

77 - 79

80 - 81

82 - 83

84

85 - 86

87

88

89 - 92

vii

LIST OF TABLES

2.1.2 Material Properties Of Thermoplastics Elastomers 13

2.1.2. l Typical Properties Of Polypropylene 16

2.6 Common Moulding Defects 27

3.3 Mesh Features 36- 37

3.4.1 Parameters Of Are Acrylonitrile Butadiene Styrene,

Polyethylene And Polypropylene 40

3.4.2 The Parameter Used For Moldflow Cooling Analysis

To Predict Cycle Times. 42

3.10 Comparison Of Process Parameters Between Straight

Cooling Channel And New Architecture Cooling Channel. 50

3.11 Comparison Mould Defects Between Straight Cooling

Channel And New Architecture Cooling Channel. 51

4.1 Parameters Of Are Acrylonitrile Butadiene Styrene,

Polyethylene And Polypropylene 53

4.2 Properties Of The Material And Machine Parameters

Used Injection Moulding Process 61

4.4 Summary Of Fill + Pack+ Cool Analysis Results

Between Straight Cooling Channel And New

Architecture Of Cooling Channel. 64

4.5.1 The Deflection, All Effects In X, Y And Z

Component 77

viii


LIST OF FIGURES

l. la Example Of Plastic Material Produce Of Injection Moulding

2

l. lb Example Of Hair Dryer Housing 3

1.1.2 2 Plate Moulds 4

1.1.3 Typical Injection Moulding Cycle Clock 5

1.1.3.l Straight Drilled Cooling Channels Are Parallel And Series 6

2.1 Plastic Injection Moulding Machine 10

2.2.1 The Moulding Cycle 17

2.3.2 Two Plate Injection Mould 19

2.4 Moulding Cycle Chart 20

2.4a Thin Shallow Part With Straight Drilled Cooling Channels 21

2.4b Thin Shallow Parts With Conformal Cooling Channels 21

2.4.la Parallel Cooling Channel And Serial Cooling Channel 22

2.4b Straight Cooling Channel 23

2.4.3 Cooling Channel Types; (A) Normal, (B) Conformal

Combination With Baffle, (C) Conventional

Combination With Conformal And (D) Conformal 25

2.6.la Flow Marks Defect 28

2.6.lb Ripples Caused By Low Temperature 28

2.6.2 Weld Lines Defects 29

2.6.3 Air Trap Defects 30

3 Flow Chart Of This Project 32

3. la 3d Model Of Body Hair Dryer Part By Using Cad Part

In Cati a V 5 Software 33

3. lb Core And Cavity Of The Body Hair Dryer 34

3.lc Parting Line And Parting Surface Of The Body Hair Dryer 34

3.2 Import Body Hair Dryer To The Autodesk

ix


Simulation Moldflow Insight 35

3.3a Change From Solid Model To 3d Mesh 38

3.3b Meshing The Body Hair Dryer Using 3d Mesh 38

3.4 Setting Up An Analysis 39

3.5a Gate Types And Properties 43

3.5b Three Common Layout Of The Runner 43

3.5c Runner Sizing Depend On Plastic Material That Will Be Used 44

3.5d Example Of Gate And Runner Placement 44

3.7 Standard Modelling Tool 45

3.7.1 Straight Cooling Channe 46

3.7.2 New Architectures Cooling Channel 47

4.la Fill Time Result For Acrylonitrile Butadiene Styrene, ABS 54

4.lb Fill Time Result For Polyethylene, PE 55

4.lc Fill Time Result For Polypropylene, PP 55

4.ld Pressure At End Of Fill Result Of Acrylonitrile

Butadiene Styrene, ABS 56

4.le Pressure At End Of Fill Result Of Polyethylene,

PE 57

4.lf Pressure At End Of Fill Result Of Polypropylene, PP 57

4.lg Volumetric Shrinkage Result For Acrylonitrile

Butadiene Styrene, ABS 58

4. lh Volumetric Shrinkage Result For Polyethylene, PE 59

4. li Volumetric Shrinkage Result For Polypropylene, PP 59

4.1.1 Comparison Between Acrylonitrile Butadiene Styrene,

Polyethylene And Polypropylene Based On Parameters Of Fill Time,

Injection Pressure And Volumetric Shrinkage 60

4.3a Straight Cooling Channel With 3d Mesh 62

4.3b New Architecture Cooling Channel With 3d Mesh 63

4.4.la Time To Reach Ejection Temperature Strainght Cooling Channel 65

4.4.1 b Time To Reach Ejection Temperature New Architecture Cooling

Channel 66

4.4.2a Time To Reach Ejection Temperature, Part Of Straight Cooling

x


Channel 67

4.4.2b Time To Reach Ejection Temperature, Part Of The New

Architecture Cooling Channel. 68

4.4.2.1 Comparison Between Straight Cooling Channel And The New

Architecture Cooling Channel Based On The Time To Reach

Ejection Temperature And Time To Reach Part Ejection

Temperature 68

4.4.3a Volumetric Shrinkage Straight Cooling Channel 69

4.4.3b Volumetric Shrinkage New Architecture Cooling Channel 70

4.4.3.1 Comparison Of Average Volumetric Shrinkage Between Straight

And New Architecture Cooling Channel 70

4.4.4a Circuit Coolant Temperature Straight Cooling Channel 71

4.4.4b Circuit Coolant Temperature New Architecture Cooling Channel. 72

4.4.4.1 Comparison Of Circuit Coolant Channel 72

4.4.5a Circuit Reynolds Number Straight Cooling Channel 74

4.4.5b Circuit Reynolds Number New Architecture Cooling Channel 74

4.4.6a The Mould Temperature Of Straight Cooling Channel 75

4.4.6b The Mould Temperature Of The New Architecture

Cooling Channel 76

4.4.6.1 Comparison Of Mould Temperature 76

4.5.la The Deflection, All Effects ln X, Y And Z Component

of Straight Cooling Channel 78

4.5.lb The Deflection, All Effects In X , Y And Z

Component of The New Architecture Cooling Channel 79

4.5.2a Weld Lines And Meld Lines Defect In The

Straight Cooling Channel. 80

4.5.2b Weld Lines And Meld Lines Defect In The New Architecture

Of Cooling Channel. 81

4.5.3a Air Traps Defects ln The Straight Cooling Channel 82

4.5 .3b Air Traps Defects ln The New Architecture Cooling Channel 8

xi


ABS

PE

pp

IM

MPI

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

Acrylonitrile Butadiene Styrene

Polyethylene

Polypropylene

Injection Moulding

Moldflow Plastic lnsight software


xii

CHAPTERl

INTRODUCTION

This thesis proposes a new architecture for cooling channel of injection

moulding. This chapter presents the background of plastic injection moulding

and the research objectives to design a new architecture of cooling channel and

simulated by using Autodesk Simulation Moldflow insight 2014 and to compare

between conventional straight cooling channel and the new architecture of the

cooling channel.

1.1 Project Background

1.1.1 Plastic Injection moulding

Nowadays, injection moulding product has been extensively used in the daily

application, such as household appliances, industrial field, toys, medical device,

electronics, computer, communication, auto parts and also in the sport equipment.

Besides, the plastic material has the advantages such as lightweight, leakproof,

durable, flexible and non-breakable compared to other material which also being

used for such applications.

1


Figure 1.l(a): Example of Plastic Material Produce oflnjection Moulding

Source: http://www.abspi.com/index.htmJ

Moreover, people are more demanding on something that simple and less

costly in their daily requirement. In order to meet customer needs, more company

struggling with competitive market to produce low cost products high quality of

product. Much research has been carried out that focusing on the increasing the

efficiency and simplify the operation, especially both assembly and manufacturing

process and cost.

This project is to analyze and simulate a hair dryer housing. The plastic

material that will be used is polypropylene (PP). In achieving the goal of creating a

new architecture of cooling channel depending on the part that have been chosen

which is hair dryer housing, the process method will be carried out by using

Autodesk simulation MoldFlow Plastics Insight software.

2


1.1.2. 2 Plate Mould

/ Sprv• buahl"9

FIG. 8.4 r •-ri..1 Ill llOfl mc. IJ

Figure 1.1.2: 2 plate moulds

Ejector pin•

The most simple and most reliable mould design is the two plate mould. It is

because normally has the fewest number of moving parts and is more straight

forward to manufacturing and run in production. 2 plate moulds are a simple

construction usually cheaper to manufacture than a complex design. Besides, the

simplicity of its design and manufacture, mould design should make sure that all

possible by using two plate design have been exhausted before other more complex

design are considered (John, 2008).

4


1.1.3. Cooling Channel

Figure 1.1.3: Typical Injection Moulding Cycle Clock

Cooling channel is the one of the parts in the injection moulding. Nowadays,

the complexity of the plastics product has increased with more features. The industry

is developing to be responsible for producing difficult geometry shapes besides to

reduce long cycle time for whole process takes place. Cooling stage plays an

important role, in fact , more than 2/3 of the cycle time depends on it solely (E. Sachs,

2000). However, the cooling time reduction will increase the production rate as well

as reduce the cost (Shoemaker, 2006). But, when decreasing the cooling time the

result will defect the part as well Meckley & Edwards,(2009). There is a need of a

cooling technique to reduce the cycle time without compromising on part quality.

(Khan et. al. , 2014)

Furthermore, in the cooling phase, heat transfers between the molten material

in the cavity and the cooling fluid flow through the cooling channels inside the

mould, until the ejection temperature are achieved and part is stable to mould. Thus,

this rate of heat exchange is very important and directly related to the time taken by

the cooling phase. So it is important to understand and optimize the cooling channel

design to optimize the rate of heat transfer in an injection moulding process. The

proper design of the cooling channel is required for a faster cooling phase.

5


Historically, the cooling channels have been created by drilling several straight holes

cooling channels inside the mould core and cavity. Such type of cooling channels is

called as Conventional Cooling Channels (khan et. al., 2014). However the cooling

process in conventional Cooling Channels is too long because of nonuniform cooling

of the part. If the part's temperature can be reduced more quickly and uniformly, it

will shorten the cooling time without compromising on part quality because nearly

uniform temperatures can be held in part by using conformal cooling Meckley &

Edwards, (2009).

1.1.3.1. Straight Cooling Channel

I I

\. J

Figure 1.1.3.1 : Straight drilled cooling channels are parallel and series

The common types of straight drilled cooling channels are parallel and series.

Parallel cooling channels are drilled straight channels that the coolant flows from a

supply manifold to a collection manifold. Cooling channels that are connected in a

single loop from the coolant inlet to its outlet are called serial cooling channels. (Park

& Dang, 2012).

6


1.1.3.2. New architecture Cooling channel

Research in new architecture cooling channel, the shape of cooling channel

has conformed to the shape of the cavity in the mold. Research of conformal cooling

channel is depending on simulation studies. Konsulova-Bakalova has used thermal

simulation software, SolidWorks Simulation, and compared conformal cooling

channels with circular and elliptical cross-sections. He has concluded that the cooling

time of the part has been optimized by using conformal cooling channels and results

translate a reduction in production cycle time and increase in the quality of the parts

("Application of solidwoks simulation for the design of the cooling system for

injection molding").

1.1.4. Project Briefing

This project aims is to optimize the cooling channel for Plastic Injection

Mould (2 Plate mould). Specifically for conventional straight cooling channel and

create new architecture of cooling channel. Nowadays, global industries are

increasing with the trend of consumer product designed that is getting smaller. Most

of the cover is made from plastic which was produced by using an injection

moulding process. It is difficult to control the defect on the part. Therefore, this study

is performed purposely to evaluate the performance of the new architecture of

cooling channel compared to the straight drilled cooling channel in order to minimize

the defect on the part . Moreover, the result can get by using simulation through

Autodesk Moldflow to get the optimization of cooling channel. However, cooling

design of plastic injection mould is important because it not only affects part quality,

but also the injection moulding cycle time.

© Universiti Teknikal Malaysia Melaka 7

1.2. Problem Statement

In every injection moulding process, the problem occurs after the molten

plastic melts turns to solidify. Several defects will appear which will affect the

performance of the part. Certain design of the cooling channel is not suitable to the

curve part if using the straight cooling channel. The major problem needs to be

concerned is the product defect. The focus should be on the cooling process of the

product that is during cooling analysis and parameter of the cooling channel for the

part which can reduce the defect. Moreover, the material also plays an important role

in reducing the defects that might appear on the part. The aim of determining which

cooling system configuration is appropriate for this part providing uniform cooling,

minimum cycle time, less warpage and shrinkage. From the research the straight

cooling channel takes a long time of cycle time, while conformal cooling channel

design gives better cycle time, which ultimately increases production rate as well as

fatigue life of the mould. It is important to determine a method to get the best result

for the future mould of this part to minimize defects.

1.3. Objective

1. To design a new architecture of cooling channel and simulated by using

Autodesk Simulation Mold flow insight 2014

2. To compare between conventional straight cooling channel and the new

architecture of the cooling channel.

8


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