Moldflow cooling simulation to reduce cycle times

 

Reduce Cycle Times by 20%.

Mould Cooling simulation allow St. Hua 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 and optimization

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.

 

Mold surface temperature

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

Cooling results for the cavity: - 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

Cooling results for the mold: - 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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