Design of conformal cooling for card holder mold

Mohd Yusof, Muhammad Hasnol Alif (2024) Design of conformal cooling for card holder mold. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This study addresses the limitations of traditional cooling channels in molds for card holder production and proposes a novel approach utilizing conformal cooling techniques. Eight main categories of conformal cooling methods are identified, including spiral and linear designs, mesh-based configurations, and modular construction methods, among others. Past examples, such as hybrid straight-drilled-conformal cooling molds, highlight the potential benefits of adopting these techniques. However, determining the superior design depends on the intricacy of the molded part. The existing design for card holder molds faces performance drawbacks, motivating the need for enhancements. This research aims to explore and propose a new mold design integrating conformal cooling to enhance efficiency and effectiveness in the card holder molding process.The main goal of this research is to optimize the layout of conformal cooling channels, utilizing computer simulations. Using a comparative analysis approach, the study establishes a conventional cooling channel as a benchmark to assess the effectiveness of various conformal cooling channel layouts. This method provides a nuanced understanding of the performance characteristics associated with each design. Results from the comparative analysis indicate that the surface-type conformal cooling channel outperforms alternative designs, demonstrating superior performance in terms of both cooling time and warpage mitigation. These findings have significant implications for production processes and product quality. The observed reduction in cooling times has the potential to substantially decrease overall cycle times in the injection molding process, thereby impacting efficiency and operational timelines. This research contributes valuable insights into optimizing cooling strategies, paving the way for enhanced manufacturing processes and improved product quality in the realm of injection molding.

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