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IHMTC2015 -1023 INVESTIGATION OF COOLING RATE ENHANCEMENT IN

THERMOPLASTIC INJECTION MOULDS WITH DIFFERENT CORE AND CAVITY
INSERT COOLING CHANNEL DESIGNS

Conference Paper · December 2015

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 Proceedings of the 23rd National Heat and Mass Transfer Conference and
1st International ISHMT-ASTFE Heat and Mass Transfer Conference
IHMTC2015
17-20 December, 2015, Thiruvananthapuram, India.

IHMTC2015 -1023

INVESTIGATION OF COOLING RATE ENHANCEMENT IN THERMOPLASTIC

INJECTION MOULDS WITH DIFFERENT CORE AND CAVITY INSERT COOLING
CHANNEL DESIGNS

K Prashanth Reddy Bhramara Panitapu G Arun Reddy

Dept. Of Mechanical Engg Dept. Of Mechanical Engg Dept. Of Mechanical Engg
ResearchScholar,JNTUCEH,Hyd. Assoc.Professor,JNTUCEH,Hyd. M.Tech.Student,GRIET,Hyd.
& Asst.Professor,GRIET,Hyd. bhramara74@jntuh.ac.in arun997.India@gmail.com
kpreddy26@gmail.com

ABSTRACT ρ - Density of coolant(kg / m3 )

The design of the cooling channels in the
thermoplastic injection moulding process is one of the A - Cross-sectional area of flow (m 2 )
most important steps during the mould design. An T - Temperature ( K )
inappropriate cooling will lead to defects in the part
and reduce the production rate due to Non-uniform t - Time ( sec )
cooling. In this paper nine different cooling channel C p - Specific heat at constant pressure ( kJ / kg .K )
designs have been investigated in the injection
moulding process. For this purpose, a cap of cosmetic k - Thermal Conductivity (W / m.K )
T2 - Temperature in the solids ( K )
product is considered. These nine cooling channel
designs are made from different combinations of
simple, conformal, parallel, and rectangular and core Qwall - Source term (W / m )
h - Heat transfer co-efficient (W / m 2 .K )
cooling channels. MoldFlow analysis tool has been
used predict the cycle time for basic profile of Cooling
Text - Temperature outside the pipe ( K )
channels, which are verified with real time
investigations at experimental setup available with the
local industry. It is found that the simulated results are Z - Perimeter of the pipe ( m )
in good agreement with the measured ones .It was
found that cooling channel designs which employ fully
Nu - Nusselt number
conformal channels on core as well as cavity side of d h - Hydraulic diameter ( m )
the mould showed best results. ∇ - Laplace operator
Keywords: Cooling Channel Design, cooling cycle, Ω - Surface area
Injection moulding and core cooling channel. h - Equivalent heat transfer co-efficient
T∞ - Equivalent ambient temperature
NOMENCLATURE T * - Weighting function

1
e j - Specific element
S - Mould surface (boundary)
P and Q - Two points on S
Te - Ejection temperature
Tm - Mould temperature
Ti - Injection temperature
α - Thermal diffusivity
s - Maximum thickness
tc - Minimum cooling time ( sec )
∂ - Normal derivative
∂n
INTRODUCTION
Polymers are already performing satisfactorily in
many applications which used to employ metal, wood,
paper, glass etc. as materials. Injection moulding is one
of the most important manufacturing process for
producing plastic parts of complex shape with highest
precision at high efficiency and low cost as highlighted
by Min et.al [1]. During the injection moulding
process, shrinkage of polymer parts is unavoidable.
Because of which air gap forms between the part and
the mould wall, thereby increasing the cooling time
required. As suggested by H. Mass, EE. Arquis et.al
existing empirical relationships become invalid due to
formation of air-gap Therefore shrinkage should be
minimum possible [2].
In injection moulding process, cycle time is a key
factor which decides the production rate. High
production rate without compromising on quality is
very much desired to meet enhancing demands and to
sustain competition. Major portion of total cycle time
is occupied by cooling phase as shown in Fig. 1.
Figure 1: CYCLE TIME IN INJECTION
MOULDING
If the part cooling time is reduced then reduction
in cycle time can be achieved. Small reduction in cycle
time may result in significant changes in production
rate especially in multi-mould cavity process. Khan
et.al asserted that Reduction in cooling time without
2
compromising on quality demands an appropriate
cooling system design [3]. Cooling system design
significantly affects the production rate and quality of
the final product. Hamdy Hassan and Nicolas Regnier
indicated that the cooling system which gives the
minimum cooling time might not achieve uniform
temperature distribution throughout the mould. The
selected cooling system design should be the one
which optimises both the tasks [4]. The cooling
channel position profoundly affects the final
temperature and volumetric Shrinkage of the product
and hence its dimensions and again the best cooling
design may not provide for optimum shrinkage, and the
one which satisfies both is to be chosen as said in the
earlier research by Hamdy Hassan et.al [5]. The gate
location in injection moulding defines how fast and
completely the mould cavity can be filled in minimum
time thereby further reducing cycle time. Nicolas
Regnier et.al proved that the minimum solidification
time during cooling and Minimum solidification of
melt during filling is possible when the gate is situated
exactly normal to the cavity’s small thickness [6]. The
variation in temperature for the core and cavity inserts
of an injection mould results in uneven or
asymmetrical cooling for the two sides of the part
being moulded which causes non uniform shrinkage
thereby producing warpage. J.G. Kovacs et.al said that
the cooling system should take into account for this
unevenness and provide a robust cooling of the parts
[7].
In the present work, nine different cooling
channels are proposed with the objective of reduction
cooling time in the total cycle time of injection
moulding process using the numerical analysis tool,
MoldFlow.
PROBLEM DEFINITION
A cosmetic product cap’s injection moulding cycle
time reduction is considered in this project, the product
is modelled in Creo and simulations are performed for
various cooling system designs using MoldFlow to find
the optimum cooling channel design.
The simulation results with a simple rectangular
cooling channel are validated with the experimental
results and further simulations are carried out with
improved cooling channel designs for further reduction
in cooling time, Which in turn reduces the mould cycle
time. The cooling simulations are run in MoldFlow
using the Boundary Element Method (BEM). From
these simulations, appropriate cooling channel design
that takes minimum time to reach ejection temperature,
part (TRET-P) with permissible volumetric shrinkage
(VS), mould surface temperature (Tmold) and warpage
or deflection (DEF) within the tolerance limits of the
final product is selected.
 A cosmetic product cap called “Oval-cap”, By making use of Green’s second identity, The
weighing about 27 gm. enclosing a volume of 40 ml above equation can be simplified as:
and made up of polypropylene, as shown in Fig. 2 is
considered for the study. 1  1 ∂T ( Q ) ∂ 1 r ( P, Q )   (5)
∫  r ( P, Q ) ∂n ( q ) − T (Q) C ( P)T ( P)
ds =
4π S
 ∂n ( q ) 

Where
1 P ∈ Ω
 (6)
C ( P ) = ∫ ∇ T d Ω = ∫ δ ( P , Q ) d Ω = 0 P ∉ Ω
2 *

Ω Ω C P ∈ S , and
 S

C is a constant in proportion to the interior solid

Figure 2: THE FINISHED PRODUCT
angle.Now the above equation only has boundary
integrations. So we divide all mould surfaces S , in to
n elements and assume the temperature and
temperature gradient are constant over each boundary
element, then the equation can be discretised into the
following form:

1  ∂ (1/ r ) 1  (7)
Minimum cooling time required [8]: C ( P)T ( P) + ∑ Te j ∫ k dS + qe j ∫
n
dS  =0
The Equation.1 as shown is used to calculate the 4π e j =1
 ∆e j ∂n ∆e j
r ( P , Q ) 
minimum cooling time for the part centreline to reach
ejection temperature The temperature influence term (or so-called H
term), which represents the influence strength of
− s 2  π (Te − Tm )  temperature on element e j to point P , is given by the
tc = ln   (1)
2πα  4 (Ti − Tm )  equation

Where s is part thickness, α thermal diffusivity, ∂ (1/ r )

Te is Ejection temperature, Ti is Melt temperature, ∫ k dS = H e j ( P ) (8)
Tm is Mould wall temperature ∆e j
∂n

Cool analysis in MoldFlow, is a true 3D mould The heat flux influence term (or so-called
cooling analysis product. It uses a numerical method
developed from BEM. From a physical point of view, G term), which represents the influence strength of
BEM treats all boundaries as heat sources (gain / loss heat flux input on element e j to point P , is given by
heat) during the solution. The temperature in the mould the equation
is determined by combining the influence from all
1
sources. The equilibrium temperature field of a 3D
mould can be represented by Laplace's equation [9]:
∫ k r ( P, Q ) dS = G ( P )
∆e j
ej (9)

 ∂ 2T   ∂ 2T   ∂ 2T 
Suppose Pi is the centroid of element i . If we
+ 2 + 2  = ∇ T = 0 ; p∈Ω (2)
2
 2 substitute P in above discretised equation with Pi ,
 ∂x   ∂y   ∂z 
then we can get n linear equations as [9]:
The above equation refers to a specific point in
that area, p , with boundary conditions unified as:
∑ (P ) + ∑ qe j Ge j ( Pi ) =
n n
=ej 1=
ej ej i ej 1
T H 0 (10)
∂T
q=
−k h (T T∞ ) ; p ∈ S
=− (3)
∂n
COOLING SYSTEM DESIGNS
To understand how BEM applies all boundary Conformal and core cooling channels are
conditions to the solution of the mould temperature considered to be the most promising designs. Notable
field, let us start with the weighted residual expression: reduction in cooling time and hence cycle time with
improved surface quality of the product were found
with conformal cooling channels as compared to
∫ ∇ TT dΩ =0 (4)
2 *
simpler designs as investigated in the earlier work by
Ω
Dimla and Miani et.al [10]. In the present study, simple

3
 rectangular, simple circular along with conformal
rectangular and conformal circular cooling channel
designs are selected. Accordingly, nine different
cooling system designs are proposed and the details are
as follows.
350C . Water is the coolant for all nine channel designs
with inlet temperature of 250C and Reynolds number
of 10000. A full analysis (Fill+Pack+Cool+Warp) has
been carried out on each and every cooling system
design and the results are obtained.

A. Simple Cooling Channel as in Fig. 3a has a Experimentation was done with the cooling
diameter of 6mm in cavity channel design D i.e., simple rectangular cooling
B. Conformal circular Cooling Channel as in channel without cooling channels in the core. Table 1
Fig.3c has a diameter of 4mm in cavity shows the comparison between the experimental and
simulation data. The simulation results with cooling
C. Conformal parallel cooling channel as in Fig.3e
channel design D are in good agreement with the
has a diameter of 4mm in cavity
experimental observations, thus validating the
D. Simple rectangular cooling channel as in figure numerical model.
4a has dimensions of 4.5mm x 23mm in cavity
E. Conformal rectangular cooling channel as in TABLE 1: VALUES FOR COOLING DESIGN D
Fig.4c has dimensions of 4.5mm x 23mm in
cavity TRET-P DEF Tmold VS
SIM/EXP
F. Simple rectangular with core-cooling channel as (sec) (mm) (0C) (%)
in Fig.5a has dimensions of 4.5mm x 23mm for
cavity and 4mm diameter in core Simulation 4.064 0.3634 54.19 0.38
G. Conformal rectangular with conformal core
Experiment 3.9 0.25 53.42 0.22
cooling channel as in Fig.5c has dimensions of
4.5mm x 23mm for cavity and 1mm X 6mm in
core
H. Conformal parallel with core-cooling channel as Sachs and Wylonis et.al proposed that Conformal
in Fig.5e has diameter of 4mm for cavity and 4 cooling channel is a cooling passage which follows the
mm diameter in core shape or profile of the mould core or cavity to perform
I. Conformal parallel with conformal core-cooling rapid uniform cooling process for injection moulding
channel as in Fig.5g has a diameter of 4mm for [11]. Simple (A), conformal circular (B) and conformal
cavity in 1mm x 6mm for core parallel (C) cooling channels without core cooling are
shown in Figs. 3a to 3f. The simulations with these
cooling channels indicate the mould surface
RESULTS AND DISCUSSIONS: temperature (Tmold) at the inner side of part to be
Among results obtained from the simulation, the maximum as shown in Figs 3a, 3c and 3e since there
output parameters, viz., time to reach ejection are no core side cooling channels.
temperature (TRET), time to reach ejection
temperature with cooling (TRET-P), warpage or
deflection (DEF) in all directions, mould temperature
(Tmold) and volumetric shrinkage (VS) are considered
for comparison. A cooling system design, which has
recorded minimum value in most of the above
parameters is the most optimised design.
The Time to reach ejection temperature (TRET)
shows the amount of time required to reach the ejection
temperature, which is measured from the start of fill.
Whereas the Time to reach ejection temperature, part
(TRET-P) result which is produced by a Cool analysis
shows the time required to reach the ejection
temperature, which is measured from the start of the
cycle. At the start of the measurement, the part is
assumed to be filled with material at its melt
temperature (Tmelt).

The simulation was carried out by assigning the

material as polypropylene for the product. The polymer
melt temperature was chosen to be 2400C. Mould
material was taken as Tool steel with density
7.8gm/cm3, specific heat 460 J/kg, Thermal FIGURE : 3 MOULD TEMPERATURE AND TRET-
conductivity 29 W/MK and a surface temperature of P FOR COOLING CHANNEL DESIGNS A,B,C
4
 Hence it infers that uneven cooling is present
because of temperature difference from outer surface
or cavity side to inner surface or core side of the
mould. Not having core side cooling channels results in
non-uniform shrinkage thereby causing warpage of
part .There is marginal drop in mould temperature
(Tmold) using conformal parallel cooling channel as
compared to cooling channel designs A and B.
The TRET-P value is almost same for cooling
channel designs A, B and C, though the conformal
parallel channel C in figure 3f showed a small decrease
in TRET-P value This drop is very minute it is due to
the increased distance of cooling channel from the
diametrical ends of cavity as compared to the simple
cooling channel A.
This is offset by the reduction in volumetric
shrinkage as seen in Tab. 2 which is because of FIGURE: 4 MOULD TEMPERATURE AND TRET-
decrease in Tmold with conformal cooling. This P FOR COOLING CHANNEL DESIGNS D AND E
decrease even though is not significant it clearly
indicates the shortening gap of temperature difference The cooling channel designs F to I as shown
from outer surface of mould or part to its inner surface. in Fig.5a to 5h incorporate cooling channels in the
cavity and core side of the mould.

TABLE: 2 RESULTS FROM ALL DESIGNS A TO I

CHANNEL TRET-P DEF Tmold VS

TYPE (sec) (mm) (0C) (%)

A 4.079 0.3557 54.63 0.4

B 4.081 0.3535 54.83 0.4

C 4.053 0.3590 53.83 0.35

D 4.064 0.3634 54.19 0.38

E 4.063 0.3648 54.11 0.37

F 3.837 0.3399 40.85 0.28

G 3.838 0.3321 36.83 0.23

H 3.833 0.3331 40.83 0.27

I 3.835 0.3343 36.83 0.23

The same phenomenon can be seen in case of

cooling system design D and E as shown in Fig. 4a to
4f .Further the cooling channel sizes have been
increased in the designs D and E leading to excess
cooling on only cavity side of mould which causes an
increase in TRET-P, DEF, Tmold and volumetric
shrinkage values when compared with cooling channel
design C
5
FIGURE: 5 MOULD TEMPERATURE AND TRET-
P FOR COOLING CHANNEL DESIGNS F, G, H
AND I
The primary difference being, having fully
conformal cooling channels on core side and cavity
side in designs G and I as compared to simple circular
core cooling channels in designs F and H. The mould
 surface temperature distribution at the core side of the
part as shown in Fig: 5a and 5e for channel designs F
and H is varying and also on the higher side whereas in
case of designs G and I the mould surface temperature
(Tmold) as shown in Fig: 5c and 5d at the core side is
almost reduced drastically, indicating a reduction in the
difference of temperatures from core to cavity side.
The results from Tab.2 indicate a remarkable reduction
in volumetric shrinkage and also warpage of the part
when compared to cooling channel designs A to E this
can be attributed to uniform heat removal in conformal
cooling. Robust cooling in both core and cavity side
causes the reduction in TRET-P or part cooling time as
shown Fig: 5d and 5h thereby reducing overall cycle
time and increasing the rate of production.
CONCLUSIONS
It can be observed that implementation of fully
conformal cooling channels on both core and cavity
gives much optimised results. As seen in designs G and
I .Uniform cooling on two sides of part and mould
inserts is achieved when compared to having just
cavity cooling channels. It is to be noted that though
the primary aim is to reduce the cooling time Excess
provision of cooling on only one side as in designs D
and E may result in decrease in dimensional accuracy
and quality of product. This further proves that cooling
time reduction is not directly dependent on cooling
system design. It is dependent on achieving uniform
mould wall temperature, which is influenced by
cooling system design. The cooling system design “I”
offers most optimal values for cooling time, shrinkage
and warpage, hence providing conformal cooling
channels in core and cavity inserts is advised.
[5] Hassan, H., Regnier, N., Pujos, C., Arquis, E., &
Defaye, G. (2010). “Modeling the effect of
cooling system on the shrinkage and temperature
of the polymer by injection molding”. Applied
Thermal Engineering, 30(13), pp. 1547-1557.
[6] Hassan, H., Regnier, N., & Defaye, G. (2009). “A
3D study on the effect of gate location on the
cooling of polymer by injection molding”.
International Journal of Heat and Fluid Flow,
30(6), pp. 1218-1229.
[7] Kovács, J. G., & Sikló, B. (2011). “Investigation
of cooling effect at corners in injection molding”.
International Communications in Heat and Mass
Transfer, 38(10), pp.1330-1334.
[8] Rosato, D. V., & Rosato, M. G. (Eds.). (2013).
Plastics design handbook. Springer Science &
Business Media
[9] Autodesk MoldFlow Insight BEM equations help
[10] Dimla, D. E., Camilotto, M., & Miani, F. (2005).
Design and optimisation of conformal cooling
channels in injection moulding tools. Journal of
Materials Processing Technology, 164, pp. 1294-
1300.
[11] Sachs, E., Wylonis, E., Allen, S., Cima, M., &
Guo, H. (2000). Production of injection molding
tooling with conformal cooling channels using
the three dimensional printing process. Polymer
Engineering and Science, 40(5), pp. 1232-1247.

REFERENCES
[1] Min, B. H. (2003). “A study on quality
monitoring of injection-molded parts”. Journal of
Materials Processing Technology, 136(1), pp.1-6.

[2] Massé, H., Arquis, E., Delaunay, D., Quilliet, S.,

& Le Bot, P. H. (2004). “Heat transfer with
mechanically driven thermal contact resistance at
the polymer–mold interface in injection molding
of polymers”. International Journal of Heat and
Mass Transfer, 47(8), pp. 2015-2027

[3] Khan, M., Afaq, S. K., Khan, N. U., & Ahmad, S.

(2014). Cycle Time Reduction in Injection
Molding Process by Selection of Robust Cooling
Channel Design. ISRN Mechanical
Engineering, 2014.

[4] Hassan, H., Regnier, N., Lebot, C., Pujos, C., &
Defaye, G. (2009). “Effect of cooling system on
the polymer temperature and solidification during
injection molding”. Applied Thermal
Engineering, 29(8), pp.1786-1791.

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