Synergy of True & Full 3D Simulation and Conformal Cooling

Key Benefits :

Warpage improvement

Cycle time reduction:about 400,000 seconds are saved

Long term unsolved quality deviation is fully resolved

Recycling of cooling fixture is eliminated and profitability is enhanced

With the more and more challenging marketing and customer demands, technologies

 which can ensure the better quality, cost performance, time to market…and etc., are

always what we would absolutely look for. This is the same for the injection molding

industry — As we know, the cooling time often occupies of 70% of the injection cycle

and critical for most of the warpage issues. When process optimization and

quality improvement is a priority, we always try to find some lights in this cooling stage.

The customer of this successful case study, Gplast, is from Coimbatore, India. With
more than three decades of experience and expertise in Tool and Die making,
injection molding and die casting, Gplast is very well known for its achievements
in Electronics, Precision Machine Tools and Transport.

Warpage is the first priority since product quality is affected a lot. However, due
 to the geometric limitation, revising process conditions or other efforts could not really
lead to satisfying enhancements. Since conformal cooling is one of the key
advantages of Gplast, it is decided to use the true and full 3D Computer
Assisted Engineering (CAE) tool to evaluate the effectiveness of the customized
cooling layout designs.

Fig. 1. Cooling channels and mold base – true 3D mesh model for simulation accuracy

One of the important concerns in this case is – the traditional 1D runner or cooling
layout is not capable for simulating correct results due to theoretical and
functional limitations.

After using Moldex3D/Solid for complete simulation of the original cooling layout
design, the analysis result shows the internal temperature is quite high and there is
a region with heat accumulation. The mold temperature difference results in the
non-uniform shrinkage – finally it leads to the warpage problem which is related
with thermal effect.

Fig. 2. Original cooling layout (left) and the mold temperature difference (right)

To improve this warpage problem, conformal cooling design is applied
 for solutions. Moldex3D is again used for performing reliable analysis via
complete and high-performance 3D simulations. After revising the cooling system,
the mold temperature difference is greatly reduced from 40°C to 6°C –
about a 85% improvement. In addition, the temperature of the corner region
(with exceeding heat in original design) is much more uniform.

Fig. 3. Revised cooling layout (left) and the mold temperature difference (right)

Compared with the original design, the Z-displacement of the revised cooling
system is reduced 25.6%. The target of the cooling system optimization is
successfully reached by such an outstanding warpage improvement. In this case,
Moldex3D simulation results are highly consistent with the real injected parts,
and prove

Fig. 4. Warpage of original design – real injected part and simulation result

 

Fig. 5. Warpage results of revised design with conformal cooling –real injected
 part and simulation result

Behind the Scene

This is just one of many successful cases done in Gplast. The synergy of true
3D Simulation and conformal cooling design capability proves not only the
quality issues like warpage can be effectively eliminated, but also the product
development cycle time would be improved. The true 3D Simulation plays an
important role – assists to identify the connections between revised cooling
designs and the results. Without these analysis results, it would be difficult
to precisely evaluate the contribution of different conformal cooling layouts.
The application of Moldex3D brings the real confidence for both product
development and the performance of conformal cooling designs.

In short, the real performances of this case include:

• Warpage Improvement
• Cycle time reduction (Annual: about 400,000 seconds are saved) 
• Productivity enhancement
• Long-term unsolved quality deviation is fully resolved.
• Recycling of cooling fixture is eliminated and profitability is enhanced.

One of the fundamental reasons for choosing Moldex3D in spite of being a customer to other CAE tools in the market was that we were looking for a professionally true and full 3D customized solution in terms of analysis and who can be a strong partner working with us in providing the best solutions. After these successful cases, we feel that Moldex3D is truly supporting for conformal cooling, and the effectiveness is satisfying. In addition, the technical support and service quality of EUC Tech and CoreTech teams is very impressive and far beyond our expectations! We are glad that we made the right decision.

Mr. G.D. Rajkumar, the Director of Gplast

About Conformal Cooling

Conformal cooling is defined as the ability to create cooling / heating configurations
 within a tool that essentially follows the contour of the tool surface or deviates
from that contour as thin / thick sections of the part may dictate for
optimal thermal management. The objective typically is to cool or heat the
part uniformly. Conformal cooling provides a tremendous advantage in mold
tooling through significant reductions in cycle times. Other than the
obvious piece-cost savings, other tangible benefits include tool, equipment
and floor space savings. (Source: Gplast)

G-PLAST (Pvt) Ltd,

GOPAL BAGH, 

1065, Avinashi Road, Coimbatore - 641 018

Tamil Nadu - INDIA