Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Cemal İrfan Çalışkan; Aliihsan Koca; Gökhan Özer; Ömer Akbal; Soner Bakır

doi:10.1007/s00170-023-11389-y

Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Cemal İrfan Çalışkan^*, Aliihsan Koca, Gökhan Özer, Ömer Akbal, Soner Bakır

^*Corresponding author for this work

Department of Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

6 Citations (Scopus)

Abstract

The stagesof this study, in which conformal cooling channels (CCCs) integrated mould core produced by LPBF (laser powder bed fusion) and CCC integrated mould core produced by SM (subtractive manufacturing), are used in a hybrid primary mould, consisting of design, numerical study, mould core production with AM (additive manufacturing) and SM, product production and mould testing with PI (plastic injection), instant thermal measurement with IRT (infrared thermography), and OM (optical microscope) examination. The findings of the transient simulation reveal that the additively manufactured CCC had a cooling time reduction of 234% when compared to the conventional straight-drilled CCC. In addition, the flow rate of the coolant in the mould core produced with AM increased approximately three times. Overall, the findings of the steady-state simulation show that the total cooling capacity of the AM-CCC arrangement is 5.9% higher than that of the traditional straight-drilled cooling channel (SM-CCC).

Original language	English
Pages (from-to)	4419-4437
Number of pages	19
Journal	International Journal of Advanced Manufacturing Technology
Volume	126
Issue number	9-10
DOIs	https://doi.org/10.1007/s00170-023-11389-y
Publication status	Published - Jun 2023

Bibliographical note

Publisher Copyright:
© 2023, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.

Funding

We would like to thank Coşkun Fırat Yıldız from Cavo R&D for his contributions to the mould design processes within the scope of this study; Yakup Aytemiz, Akif Öner, Ersin Güney, and Erdoğan Kızılca from Cavo Otomotiv for their support in SM mould production processes; and Bahattin Ekinci for his support in production and material supply and PI printing processes. This numerical part of the study has been financially supported by Istanbul Technical University Scientific Research Projects Coordination Department, Project ID: 44056.

Funders	Funder number
Coşkun Fırat Yıldız
Istanbul Teknik Üniversitesi	44056

Keywords

Additive manufacturing
Conformal cooling channels
DFAM (design for additive manufacturing)
Laser powder bed fusion
Subtractive manufacturing

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1007/s00170-023-11389-y

Cite this

Çalışkan, C. İ., Koca, A., Özer, G., Akbal, Ö., & Bakır, S. (2023). Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application. International Journal of Advanced Manufacturing Technology, 126(9-10), 4419-4437. https://doi.org/10.1007/s00170-023-11389-y

@article{ea96ce362d76411694def15c5a0126c3,

title = "Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application",

abstract = "The stagesof this study, in which conformal cooling channels (CCCs) integrated mould core produced by LPBF (laser powder bed fusion) and CCC integrated mould core produced by SM (subtractive manufacturing), are used in a hybrid primary mould, consisting of design, numerical study, mould core production with AM (additive manufacturing) and SM, product production and mould testing with PI (plastic injection), instant thermal measurement with IRT (infrared thermography), and OM (optical microscope) examination. The findings of the transient simulation reveal that the additively manufactured CCC had a cooling time reduction of 234% when compared to the conventional straight-drilled CCC. In addition, the flow rate of the coolant in the mould core produced with AM increased approximately three times. Overall, the findings of the steady-state simulation show that the total cooling capacity of the AM-CCC arrangement is 5.9% higher than that of the traditional straight-drilled cooling channel (SM-CCC).",

keywords = "Additive manufacturing, Conformal cooling channels, DFAM (design for additive manufacturing), Laser powder bed fusion, Subtractive manufacturing",

author = "{\c C}alı{\c s}kan, {Cemal İrfan} and Aliihsan Koca and G{\"o}khan {\"O}zer and {\"O}mer Akbal and Soner Bakır",

note = "Publisher Copyright: {\textcopyright} 2023, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.",

year = "2023",

month = jun,

doi = "10.1007/s00170-023-11389-y",

language = "English",

volume = "126",

pages = "4419--4437",

journal = "International Journal of Advanced Manufacturing Technology",

issn = "0268-3768",

publisher = "Springer London",

number = "9-10",

}

Çalışkan, Cİ , Koca, A, Özer, G, Akbal, Ö & Bakır, S 2023, 'Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application', International Journal of Advanced Manufacturing Technology, vol. 126, no. 9-10, pp. 4419-4437. https://doi.org/10.1007/s00170-023-11389-y

Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application. / Çalışkan, Cemal İrfan ; Koca, Aliihsan; Özer, Gökhan et al.
In: International Journal of Advanced Manufacturing Technology, Vol. 126, No. 9-10, 06.2023, p. 4419-4437.

Research output: Contribution to journal › Article › peer-review

TY - JOUR

T1 - Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds

T2 - a hybrid application

AU - Çalışkan, Cemal İrfan

AU - Koca, Aliihsan

AU - Özer, Gökhan

AU - Akbal, Ömer

AU - Bakır, Soner

PY - 2023/6

Y1 - 2023/6

N2 - The stagesof this study, in which conformal cooling channels (CCCs) integrated mould core produced by LPBF (laser powder bed fusion) and CCC integrated mould core produced by SM (subtractive manufacturing), are used in a hybrid primary mould, consisting of design, numerical study, mould core production with AM (additive manufacturing) and SM, product production and mould testing with PI (plastic injection), instant thermal measurement with IRT (infrared thermography), and OM (optical microscope) examination. The findings of the transient simulation reveal that the additively manufactured CCC had a cooling time reduction of 234% when compared to the conventional straight-drilled CCC. In addition, the flow rate of the coolant in the mould core produced with AM increased approximately three times. Overall, the findings of the steady-state simulation show that the total cooling capacity of the AM-CCC arrangement is 5.9% higher than that of the traditional straight-drilled cooling channel (SM-CCC).

AB - The stagesof this study, in which conformal cooling channels (CCCs) integrated mould core produced by LPBF (laser powder bed fusion) and CCC integrated mould core produced by SM (subtractive manufacturing), are used in a hybrid primary mould, consisting of design, numerical study, mould core production with AM (additive manufacturing) and SM, product production and mould testing with PI (plastic injection), instant thermal measurement with IRT (infrared thermography), and OM (optical microscope) examination. The findings of the transient simulation reveal that the additively manufactured CCC had a cooling time reduction of 234% when compared to the conventional straight-drilled CCC. In addition, the flow rate of the coolant in the mould core produced with AM increased approximately three times. Overall, the findings of the steady-state simulation show that the total cooling capacity of the AM-CCC arrangement is 5.9% higher than that of the traditional straight-drilled cooling channel (SM-CCC).

KW - Additive manufacturing

KW - Conformal cooling channels

KW - DFAM (design for additive manufacturing)

KW - Laser powder bed fusion

KW - Subtractive manufacturing

UR - http://www.scopus.com/inward/record.url?scp=85153084878&partnerID=8YFLogxK

U2 - 10.1007/s00170-023-11389-y

DO - 10.1007/s00170-023-11389-y

M3 - Article

AN - SCOPUS:85153084878

SN - 0268-3768

VL - 126

SP - 4419

EP - 4437

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

IS - 9-10

ER -

Efficiency comparison of conformal cooling channels produced by additive and subtractive manufacturing in automotive industry plastic injection moulds: a hybrid application

Abstract

Bibliographical note

Funding

Keywords

UN SDGs

Access to Document

Other files and links

Fingerprint

Cite this