D03-02-003

Conformal Cool
Case Study
December, 2016
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2
 What to Learn

> Learning objectives

– Interpretation of results through case study

– Common problems in Conformal Cooling molding

> Moldex3D version

– Supported since R12

> Recommended user

– Recognize Conformal Cooling molding analysis technique

3
 Contents

> Case study 1

– Syringe Model
> Case Study2
– Carriage Model
> Case Study 3
– Cup Model
> Case Study 4
– Machine Tool Cover Model

4
Case study 1
Syringe Model
 Syringe Model

Dimension:
Length: 123.5 mm
Width: 60 mm
Height: 24 mm
Thickness: 1.5~2 mm

Moldbase material: NAK80

Part material: PC
Ejection temperature: 135 ℃
Mold temperature: 80/100 ℃
Cooling time: 20 sec

6 The cooling channel layout

 No Cooling Channel Layout

No cooling channel

7
 Baffle Cooling Channel Layout

Ø8

Ø6
Baffle

8
 Conformal Cooling Channel Layout

Ø3

Ø6
Conformal

9
 Result Comparison

Part temperature distribution at EOC

No cooling channel Baffle Conformal

100.853~138.804 ℃ 100.118~138.327 ℃ 100.017~128.31℃

10
 Transient Temperature Result – No Cooling

EOC temperature distribution Temperature animation

97.557℃~138.895℃

11
 Transient Temperature Result – Baffle

EOC temperature distribution Temperature Animation

97.532℃~138.501℃

12
 Transient Temperature Result – Conformal Cooling

EOC temperature distribution Temperature Animation

97.972℃~131.697℃

13
 Result Comparison

Mold temperature difference

No cooling channel Baffle Conformal

0~35.571 ℃ 0~35.101 ℃ 0~25.679℃

14
 Result Comparison

Cooling Time

No cooling channel Baffle Conformal

23.685 sec 23.678 sec 22.49 sec

15
 Result Comparison

> Total displacement

No cooling Baffle Conformal

0.0184~0.2023mm 0.0191~0.2051 mm 0.0184~0.2018mm

16
 Result Comparison

> Total thermal displacement

No cooling Baffle Conformal

0.0659~0.4818mm 0.0587~0.4597 mm 0.0582~0.4534mm

17
 Result Summary – Tmold = 100 ℃

No cooling w/ Baffle w/ Conformal Cooling

EOC part temperature (℃) 100.853~138.804 100.118~138.327 100.017~128.31 (10.5℃ lower)

Mold temperature difference (℃) 0~35.571 0~35.101 0~25.679 (9.9℃ Lower)

Cooling time (sec) 23.685 23.678 22.49 (1.2 sec. shorter)

Total displacement (mm) 0.0184~0.2023 0.0191~0.2051 0.0184~0.2018 (0.2% less)

Total thermal displacement (mm) 0.0659~0.4818 0.0587~0.4597 0.0582~0.4534 (5.9% less)

18
 Result Summary – Tmold = 80℃

No cooling w/ Baffle w/ Conformal Cooling

80.2~129.3
EOC part temperature (℃) 81.6~136.5 80.2~118.9 (17.6℃ lower)
(7.2℃ lower)

0~31.0
Mold temperature difference (℃) 0~44.4 0~1.7 (42.7℃ lower)
(13.4℃ lower)

0.2~19.3
Cooling time (sec) 0.2~20.3 0.2~17.7 (2.6 sec. shorter)
(1 sec. shorter)

0.019~0.192
Total displacement (mm) 0.018~0.196 0.016~0.187 (4.6% less)
(2.0% less)

0.044~0.351
Total thermal displacement (mm) 0.059~0.418 0.043~0.341(18.4% less)
(16.0% less)

19
Case Study2
Carriage Model
 Carriage Model

> As shown in the figure below, the hallow interior of this

part is the crucial area. With traditional cooling channel
design, this is mostly the area with heat accumulation.
This will cause inward warp during injection molding
process.

21
 Cooling Channel Design

> The conventional design has no cooling channel inside

the hallow interior. With conformal cooling design, warp
can be reduced.

Conventional Conformal

22
 Conventional Cooling Design
Process condition: Material:
Filling time = 0.421684 seconds Type: Thermoplastic
Injection pressure = 240 MPa Generic Name: ABS
Packing pressure = 240 MPa Supplier: A. Sohulman
Packing time = 5 seconds Trade Name: Polyman HH3
VP switch-over = 98% Melt Temp range: 220 - 260℃
Melt temperature = 240℃ Mold Temp range: 40 - 80℃
Ejection Temp: 106℃
Mold temperature = 60℃
Freeze Temp: 126℃
Cooling Time = 20 seconds
Mesh Information:
Dimension:
Part Dimension: 90.67x57.15x12.85mm
Mold Dimension: 124x215x120mm
Volume:
Cavity (Part) Volume : 15.244 cc
Cold Runner Volume : 0.779987 cc
Part Element: 890,091
23
 Conformal Cooling Design
Process condition: Material:
Filling time = 0.421684 seconds Type: Thermoplastic
Injection pressure = 240 MPa Generic Name: ABS
Packing pressure = 240 MPa Supplier: A. Sohulman
Packing time = 5 seconds Trade Name: Polyman HH3
VP switch-over = 98% Melt Temp range: 220 - 260℃
Melt temperature = 240℃ Mold Temp range: 40 - 80℃
Ejection Temp: 106℃
Mold temperature = 60℃
Freeze Temp: 126℃
Cooling Time = 20 seconds
Mesh Information:
Dimension:
Part Dimension: 90.67x57.15x12.85mm
Mold Dimension: 124x215x120mm
Volume:
Cavity (Part) Volume : 15.244 cc
Cold Runner Volume : 0.779987 cc
Part Element: 890,091
24
 Cooling Analysis – Cooling Temperature

Conventional Cooling Conformal Cooling

Cooling Temperature Cooling Temperature

60.650 ~ 114.647 ℃ 60.388 ~ 69.126 ℃

25
 Cooling Analysis – Cooling Times
Conventional Cooling Conformal Cooling

Cooling Time Cooling Time

26
 Cooling Analysis – Cooling Efficiency
Conventional Cooling Conformal Cooling

Cooling Efficiency

27
 Cooling Analysis – Mold Temp Difference
Conventional Cooling Conformal Cooling

Mold Temp Difference

Mold Temp Difference

28
 Cooling Analysis – Mold Temperature

> The two figures below show the mold temperature

distribution of conventional and conformal cooling design.
We can see the maximum temperature drops from 114.7
℃ to 69.2 ℃

Conventional Cooling Conformal Cooling

29
 Warpage Analysis – X Displacement

Conventional Cooling Conformal Cooling

X Displacement = X Displacement =
-0.2512 ~ 0.2439 mm -0.2585 ~ 0.2499 mm

30
 Warpage Analysis – Y Displacement

Conventional Cooling Conformal Cooling

Y Displacement =
Y Displacement =
-0.098 ~ 0.122 mm
-0.113 ~ 0.133 mm

31
 Warpage Analysis – Z Displacement

Conventional Cooling Conformal Cooling

Z Displacement = Z Displacement =
-0.677 ~ 0.655 mm -0.084-0.086 mm

32
 Warpage Analysis – Total Displacement

Conventional Cooling Conformal Cooling

Total Displacement = Total Displacement =

0.001 ~ 0.685 mm 0.001 ~ 0.265mm

33
 Result Summary

> For this case, the z-direction warp is the most concerned
point. Compare the conventional cooling system design
with conformal design, z-direction warp reduced by 87%.

Conventional Conformal Improved

(%)
X -0.2512 ~ 0.2439 -0.2585 ~ 0.2499 -3
mm mm
Y -0.113 ~ 0.133 -0.098 ~ 0.12mm 11
mm
Z -0.677 ~ 0.655 -0.084 ~ 0.086 87
mm mm
Total 0.001 ~ 0.685 mm 0.001 ~ 61
0.265mm

Displacement comparison

34
 Result Summary

> From the photo of actual product, we can also see the
warpage improvement is significant in z direction.

Conventional Cooling Conformal Cooling

35
Case Study 3
Cup Model
 Cooling channel design change

Cup Model
> Length: 90 mm
> Width: 90 mm
> Height: 120 mm
> Thickness: 2 mm

37
 Mesh
Conventional design

Conformal design

38
 Coolant Streamlines (Conventional)

39
 Coolant Streamlines (Conformal)

40
 Coolant Velocity (Conventional)

41
 Coolant Velocity (Conformal)

42
 Sensor Node Positions

SN3 Sensor node

SN4

SN5

SN6

SN7

SN8

SN9

43
Temperature History at Sensor Nodes (Conventional)

Cooling rates at each node are not the

same, this will affect product quality. EOC
product surface temperature is 84~91ºC,
temperature difference is 5~7ºC.

Flow Pack Cool Open

44
 Temperature History at Sensor Nodes (Conformal)

Cooling rates at each node are closer than

traditional cooling. EOC product surface
temperature is 80.5~81.5ºC, temperature
difference is 2~3ºC.

45 Flow Pack Cool Open

 Case Result Summary

Conventional Conformal

Temperature
82-91ºC 80-82ºC
distribution

Temp. range 75-103ºC 75-98ºC

Moldbase temperature 79-91ºC 79-84ºC

Temp. range 79-105ºC 79-98ºC

1. Cooling rates at each 1. Cooling rates at each node

node are not the same, this
will affect product quality.
Temperature History at
Sensor Nodes 2. EOC product surface
temperature is 84~91ºC,
temperature difference is
5~7ºC.
are closer than conventional
cooling.
2. EOC product surface
temperature is 80.5~81.5ºC,
temperature difference is
2~3ºC.

46
Case Study 4
Machine Tool Cover Model
 Machine Tool Cover Model

> As shown in the figure below, this model has a very

complex geometry. Also, thickness variation is large.
> With conformal cooling channel design, cooling time was
dropped by 10 seconds (33%).

48
 Case Model

Length:162.23 mm Sprue
Width:105.15 mm
Height:44.51 mm

Part

Runner

Thickness: 0.001 – 6.42mm

Material: ABS (Techno ABS350)

Ejection Temperature: 97℃
Mold Temperature: 60℃
Cooling Time: 20s
49
 Cooling System

Normal (Baffle) Conformal

Coolant type: water

Coolant Temperature: 60℃
Coolant Flow Rate: 116 cc/sec
50
 Conformal Cooling Channel Design
Resin model with conformal
cooling pipes

Two cooling channels

IN１

IN２

OUT２ OUT１
51 51
 Venting Design

Decrease electric consumption, increase product quality, venting, lower forming

pressure. Using density control to improve venting and solve the burning problem.

2 gates

52
 Mold Picture

Cavity Core

53
 Normal Cooling – EOC Temperature

The highest temperature area is

shown at the red circle below.
There is obvious no cooling
channel going through this area.

Part surface temperature

distribution at EOC
60.04 – 134.02 ℃

Mold temperature: 60 ℃ Bottom View

54
 Normal Cooling – EOC Temperature

The figures show the iso-surface of part

temperature at EOC.
The highest temperate is located at the
red circle area.

Part temperature distribution at EOC

(iso-surface)
Area shown in the figure: 198.83 ℃
Temperature Range:
59.09 – 201.68 ℃
Bottom View
Mold temperature: 60 ℃
55
 Normal Cooling – Cooling Time

Cooling time is defined as the time

required to cooling down to ejection
temperature since the end of packing.
Thus, our default cooling time (20sec) is
insufficient.

Max. cooling time required:

103.62 seconds

Cooling time distribution (iso-surface)

Area shown in the figure: 101.55 sec
Range: 0.37 – 103.62 sec

Mold temperature: 60 ℃

56
 Conformal Cooling – EOC Temperature

The highest temperature area is

shown at the red circle below.
There is obvious no cooling
channel going through this area.

Part surface temperature

distribution at EOC
57.82 – 129.95 ℃

Mold temperature: 60 ℃

Bottom View
57
 Conformal Cooling – EOC Temperature

The left figure shows the iso-surface of

part temperature at EOC.
The highest temperate is located at the
red circle area.

Part temperature distribution at

EOC (iso-surface)
Area shown in the figure: 195.4 ℃
Temperature Range:
57.82 – 199.67 ℃
Bottom View
Mold temperature: 60 ℃
58
 Conformal Cooling – Cooling Time

Cooling time is defined as the time

required to cooling down to room
temperature since the end of packing.
Thus, our default cooling time (20sec) is
insufficient for conformal cooling design.

Max. cooling time required:

96.51 seconds

Cooling time distribution (iso-surface)

Area shown in the figure: 100 sec
Range: 0.11 – 96.51 sec

Mold temperature: 60 ℃
59
 EOC Temperature Comparison

If we set the same temperature range for the

two cases, we can see that conformal
cooling channel effectively remove most the
heat at the core side. However, the max.
temperature area still exists since no cooling
channel pass that area (red circles).

Normal cooling, bottom view

Mold temperature: 60 ℃ Conformal cooling, bottom view

60
 Cooling Efficiency Comparison

There is no surprise that conformal cooling

channel has the highest efficiency (53.73).
Instead, the baffle cooling channel has a
very low efficiency (1.16%)

Normal cooling, 35.5/64.5 %

Since the baffle design does not

reach the core side of cavity, the
lower cooling channel only absorbs
1/3 of the total heat.
Conformal cooling, 1.16-53.73%
Mold temperature: 60 ℃
61
 Cycle Time Comparison – Experiment

Mold Nozzle First Stage Second Stage Third Stage

Temperature=50℃ ２１０℃ ２１０℃ ２００℃ １９０℃

29sec has sink mark 21sec runner deform

Sink mark
30sec

OK
Traditional

Cycle time 53sec/cooling

29sec 21sec 19sec NG
30sec

20sec
DMLS Cooling time reduce 10
seconds (33％ reduction) OK
＋gate set
62 62
Cycle time 43sec/cooling 20sec
 Sink Mark Results Comparison

Normal (cooling time = 30 sec) Conformal (cooling time = 20 sec)

displacement: 0 – 0.148mm displacement: 0 – 0.105mm

> Sink marks appear on real product at the

Sink marks
places pointed out in the right figure. In
simulation results, sink mark values are
relatively close for the two cooling systems:
Normal: 0.07mm
Conformal: 0.08mm

63
 Result Summary & Conclusion

> In the normal (baffle) cooling channel design, the

efficiency is not that good since the cooling channels do
not reach the core side of cavity.
> In this case study, we can see conformal cooling design
can lower cooling time effectively (7.1 seconds). However,
the highest temperature area is still hard to cool since
cooling channel is not easy to reach.
> Sink mark location is close to the real product and the
values are relatively close for the two cooling systems.

EOC temperature (℃) Cooling Time (Seconds)

Normal 59.09 – 201.68 0.37 – 103.62

Conformal 57.82 – 199.67 0.11 – 96.51

64
 Suggestions for Improvement

> To further decrease cooling time, there are couple of ways:

– Due to the manufacture limitation (the width of the upper
right circle area is only 4mm), it may not be possible to add
additional cooling channel in the heat accumulated (red
circle) area. One possible way is to use high conductivity
material at that area.
– Another possible solution is part re-design: core out the part
thickness.

65