CASE STUDY FOR L560 CASE FRAME TOOL

- CANGMING 3D TECH CO.,LTD - EDIT BY: ALAN SUN

Contents 1, Mold flow analysis for the hot spot; 2, conformal cooling circuit design; 3, split for the inserts; 4, Mold flow analysis with conformal cooling; 5, DMLS inserts with 3D Hybrid printing; 6, Heat-treatment and past machining process; 7, Trial off 8, Summary

Initial Mold flow Analysis with traditional cooling circuit

Part name: PF Case Frame Project: XXXX

Part No.: LH-RH-3D Volume:

Weight： Cavity: 1+1

Material： (PBT+50GF) Analyser: Shi Zhen Ye

Vision： Format: PRT

Material Property PBT+ 50% Glass Fiber

Initial Mold flow Analysis with traditional cooling circuit

Temperature with 80 ℃ water

Initial Mold flow Analysis with traditional cooling circuit

There is some hot spot, the temperature is up to 167 ℃ in tradition cooling circuit

Initial Mold flow Analysis with traditional cooling circuit

Water temperature: 80 ℃

Identified the hot spot area. The hottest area is167 ℃， most area with 90 ℃

Temperature, mold Initial Mold flow Analysis with traditional cooling circuit

Design the conformal cooling in according to the mold flow analysis. To eliminate the hot spots.

Cavity Inserts with Conformal cooling

Φ2.0 mm

Do the conformal cooling design and make the conformal cooling inserts.

Conformal cooling inserts

Φ3.0mm

DMLS CUSION inserts, 1.2709 HRC50+/-2

Base Plate: 1.2344 HRC50

Do the conformal cooling design, make the conformal cooling inserts, and make the 2nd Mold flow analysis

This is serial cooling channel, not good design. Shall change to parallel cooling channel. Redesign

Mold temperature: 100 deg. C Melt temperature: 265 deg. C V/P switch over (%) : 97% Fill Time 1.8s

Pack/hold pressure profile (rel): duration % filling pressure ------------ ---------------- 0 s 80 11 s 80 3 s 0

Do the conformal cooling design and make the conformal cooling inserts. Do the conformal cooling design, make the conformal cooling inserts, and make the 2nd Mold flow analysis

Significantly improvement of temperature on the hot spot area.

Do the conformal cooling design and make the conformal cooling inserts. Do the conformal cooling design, make the conformal cooling inserts, and make the 2nd Mold flow analysis

With cooling time in 36 seconds with traditional cooling circuit.

Do the conformal cooling design, make the conformal cooling inserts, and make the 2nd Mold flow analysis

With cooling time in 13.3 seconds with traditional cooling circuit.

Fill up time (S) Packing Time (S) Cooling Time (S) Mold movement Time (S) Cycle Time (S)

Traditional cooling circuit 1.8s 12s 36s 10s 60

Conformal Cooling Circuit 1.8s 12s 14s 10s 38s

Do the conformal cooling design, make the conformal cooling inserts, and make the 2nd Mold flow analysis

Summary from Mold Flow Analysis： The CCC cooling time of 14s , and the TCC cooling time of 36s .

The whole cycle time is from 60s to 38s, with a reduction of cycle at 36%.

Manufacturing with DMLS inserts

Base Plate: Uddeholm 1.2344 , Heat treatment to HRC48-52 before DMLS CUSING

Manufacturing with DMLS inserts

1.2709 (CL50WS), Heat treatment to HRC48-52 after clean of powder , water testing for cooling channel. And then post machining and assembling in the tool.

DMLS CUSING INSERTS WITH CONFORMAL COOLING

Manufacturing with DMLS inserts

DMLS CUSING INSERTS WITH CONFORMAL COOLING

Protection of Water Circuit

A small filter to installed in the circuit for filtering the chips.

Protection of Water Circuit

Soften the water to prevent scale. (calcification, CaCO3) A small filter to installed in the circuit for filtering the chips.

Tool trial off result

Fill up time (S) Packing Time (S) Cooling Time (S) Mold movement Time (S) Cycle Time (S)

Traditional cooling circuit 1.8 12 36 10 60

Conformal Cooling Circuit 1.8 12 12 10 36

Result from the actual trial off

Summary from Actual Tool Trial off 1, The whole cycle time is reduce from 60S to 36S, with a reduction of cycle at 36%. 2, The limitation of cooling is come from other area of parts. For the conformal cooling area, it is OK even with 36S cycle time.

钢料镶件

DMLS Insert with Conformal cooling

OK with 60 Second Cycle Time

Tool trial off result

Traditional Cooling

OK with 60 Second Cycle Time

With sticking and whiten with 46 second cycle time

OK with 46 Second Cycle Time

Traditional Cooling DMLS Insert with Conformal cooling

OK with cycle time 36s , but it start to sticking in other area of the product.

Serious sticking with cycle time 36s.

钢料镶件 Traditional Cooling DMLS Insert with Conformal cooling

After we have polishing in this area, it finally achieve 36s cycle time.