Automated derivation of straight tempering channels for optimized thermal management in injection molding tools
A new Python-based approach enables the automated design of straight cooling channels in injection molds. Adapted path-finding algorithms are used to develop locally optimized, collision-free layouts that minimize distortion and ensure thermal efficiency – a step towards standardization and cost reduction in thermal tool design.
Initial situation / problem:
The thermal design of injection molds is usually a complex and iterative process.
construction process, which is still only automated to a limited extent. Cooling channel layouts are designed manually and the result is subjective and dependent on experience. This means that the local cooling requirement of the moulded part is not realized in its entirety. IKV is investigating approaches to achieve the automated creation of cooling channels and thus accelerate the thermal design and realize components with minimal distortion potential.
The minimization of the distortion is achieved during the optimization by an evenly distributed
shrinkage potential, which is based on a homogeneous cooling rate and temperature distribution. An existing algorithm enables the derivation of near-contour temperature control channels, but these must be produced using additive manufacturing processes.
Additive manufacturing of tool inserts offers more geometric freedom than drilling
of straight cooling ducts, but the process is significantly more cost-intensive and maintenance is more difficult.
and preparation of the channels is more complex.
Objective:
Based on the results of an existing algorithm for optimizing local heat flows, an automated derivation of straight cooling channels is created using the Python programming language. The aim is to minimize the influence of the user and to minimize
Consideration of the manufacturing and operational boundary conditions. Possible collisions with the molded part and other relevant areas in the mold, such as parting lines, must be avoided.
Solution and results:
Within the existing design routine, the approximation and path-finding algorithms are adapted to the target. To this end, significant nodes are identified and
calculates the best combination of connecting these points with straight-line segments. The influence of the generated straight-line channels is then simulated using a complex
molded part and compare it with the results of an existing manually designed cooling channel layout. Distortion and thermal process variables are used as quality parameters.
for the generated cooling channel layout.
Project data and funding
The work presented is financially supported by the German Research Foundation (DFG) as part of the Collaborative Research Center 1120 “Component precision through control of melt and solidification in production technology” in sub-project B01 (“Algorithms for designing a temperature control layout for injection molds taking into account local cooling requirements”). Our sincere thanks go to her.
Project duration: