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Abstract

Thequalityofaninjectionmoldedpartislargelyaffectedbythemoldcooling.Consequently,thismakesitnecessarytooptimizethemoldcoolingcircuitwhendesigningthepartbutpriortodesigningthemold.Variousapproachesofoptimizingthemoldcoolingcircuithavebeenproposedpreviously.Inthiswork,optimizationofthemoldcoolingcircuitwasautomatedbyacommercialprocessintegrationanddesignoptimizationtoolcalledProcessIntegration,Automationand

Optimization（PIAnO）,whichisoftenusedforlargeautomotivepartssuchasbumpersandinstrumentpanels.Thecoolingchannelsandbaffletubeswerelocatedontheoffsetprofileequidistantfromthepartsurface.Thelocationsofthecoolingchannelsandthebaffletubeswereautomaticallygeneratedandinputintothemoldcoolingcomputer-aidedengineeringprogram,AutodeskMoldflowInsight2010.Theobjectivefunctionwasthedeviationofthemoldsurfacetemperaturefromagivendesigntemperature.Designvariablesintheoptimizationwerethedepths,distancesanddiametersofthecoolingchannelsandthebaffletubes.Foramorepracticalanalysis,thepressuredropandtemperaturedropwereconsideredthelimitedvalues.Optimizationwasperformedusingtheprogressivequadraticresponsesurfacemethod.Theoptimizationresultedinamoreuniformtemperaturedistributionwhencomparedtotheinitialdesign,andutilizingtheproposedoptimizationmethod,asatisfactorysolutioncouldbemadeatalowercost.

Keywords:

Injectionmolding,Coolingchannel,Coolinganalysis,PQRSM,Designoptimization

1.Introduction

Thecoolingstageisthelongeststageduringthecycletimeoftheinjectionmoldingprocess.Therefore,themosteffectivemethodtoreducethecycletimeistoreducethecoolingtime.Thecoolingtimeisfundamentallydeterminedbythepartthicknessandmoldtemperature,whichcreatesacoolingtimelimitation.Ifthemoldtemperatureandpartthicknessareuniformoverawholepart,thecoolingtimeisnotaconcern;

however,non-uniformpartthicknessandmoldtemperaturedistributionlengthentheoverallcoolingtime.Alongercoolingtimemeanspoortemperatureuniformity,whichcancausetheparttowarp.Thisisespeciallytrueforlargeproducts,suchasautomotivebumpersandinstrumentpanels.Itisforthesetypesofpartsthattemperatureuniformitybecomesthemostimportantfactorinmolddesign.

Wedevelopedanautomatedoptimizationofthecoolingcircuitforanearlypartdesigninordertocheckthedesignvalidity.Usuallytheearlypartdesignischeckedbythefiling/packingandwarpageanalyseswithoutacoolinganalysis.Thisisbecausetheassumptionisthatthemoldtemperatureisuniform,whichisnotactuallytrue.Providingarapidlyoptimizedcoolingcircuitforthedesignedpartwouldhelppartdesignerscorrecttheirdesign

Theoptimizationwasdesignedtominimizetheparttemperaturedeviationusingdesignvariablessuchasthediametersanddistancesofthecoolingchannelsandbaffletubesandthedepthsofthepartfromthemoldsurfaceofthecoolingchannelsandbaffletubes.Acommercialcomputeraidedengineering（CAE）tool,AutodeskMoldflowInsight,wasusedforthecoolinganalysis.Wesuccessfullyobtainedanoptimizedcoolingcircuitinatimemuchshorterthancanbeachievedinamanualdesign.Inordertodeveloptheautomatedoptimizationofthecoolingcircuitforthepracticalmolddesign,practicaldesignparameterssuchasthepressuredroplimitandthecoolanttemperaturerisewereconsideredintheoptimization.

Theperformanceoftheoptimizationtechniquecanbeaffectedbynumericalnoiseintheresponses.Tofindanoptimumsolutioneffectivelywhennumericalnoiseexists,weperformedanoptimizationbyapplyingaregressionbasedsequentialapproximateoptimizerknownastheProgressiveQuadraticResponseSurfaceMethod（PQRSM）（Hongetal.,2000）,whichwaspartofacommercialprocessintegrationanddesignoptimization（PIDO）toolknownastheProcessIntegration,Automationand

Optimization（PIAnO）（FRAMAX,2009）.

Figure1.Finiteelementmodeloftheproductusedfortheoptimization.

2.MODELANDCHANNELCONFIGURATION

2.1.ModelConfiguration

ThemodelusedfortheoptimizationandCAEanalysiswasanautomotivefrontbumper（FB）.Thesizeofthepartwas1,800×

600mm,theelementtypewastriangularandthenumberofelementsinthemodelwasapproximately

26,000,withanaverageaspectratioof1.5.ThemodelisshowninFigure1.

2.2.CoolingChannelConfiguration

Thecoolingcircuitfortheautomotivebumpermoldistypicallydesignedtohaveahorizontalplaneoflinecoolingchannelsandtoinstallbaffletubesfromthelinecoolingchannels.However,inthisdesign,unnecessarilylongbaffletubesattache