Design of conformal cooling channels by numerical methods in a metal mold and calculation of exergy destruction in channels

Abstract

Shorter cycle times, better product quality, and less product outage can be achieved with faster cooling. However, mold cooling channels can only be made in linear directions and limited forms via classical manufacturing methods. Therefore, they limit the performance of mold cooling. Developed in recent years, additive manufacturing technologies are capable of building complex geometries and monoblock 3D products. With this technology at hand, it is possible to produce metal molds with conformal cooling channels in diferent forms that are capable of qualified cooling. In this study, conformal cooling channels were designed in order to achieve optimum cooling in monoblock permanent mold. In this study, CFD (Computational Fluid Dynamic) analyses are performed in steady state conditions for designed conformal cooling channels and classical cooling channel mold. Pressure drops, cooling channel outlet temperatures, and exergy destructions are calculated based on the flow velocity rate in channels. The numerical investigations of the cooling process have shown that approximately cooling performance of 5% or higher can be achieved with conformal cooling channels. However, pressure drop in the conformal cooling is observed to be higher than classical cooling channel. In addition, exergy destruction in the conformal cooling channel is approximately 12% greater than that in the classical cooling channel.