Finite Element Simulation of Injection Mold Design Integrating Different Structures of Conformal Cooling Channels

Injection molding (IM) is a process in which completely melted plastic material is injected into the mold cavity under high pressure at a specific temperature, and the molded product is obtained after pressure holding, cooling, and demolding. During the mold cooling process, the conformal cooling channel system can improve the uniformity of mold temperature, reduce warping deformation, and significantly improve product accuracy. However, the cost consumption of conformal cooling channels for the cavity and core of injection molds is significant, which is a distinct disadvantage. This paper proposes an innovative conformal cooling channel. Compared with conventional cooling channels, the warpage of plastic parts has been reduced by 0.3401 mm. Moreover, the cooling time difference between C2 and C4 is relatively small, about 7.9 s. Among them, C4 takes the shortest time, C1 takes the longest, and C4 is 4.371 s shorter than C1. Compared with C1, the cooling efficiency of C4 has increased by 35.48%. In addition, from a commercial value perspective, many mold manufacturing companies’ real production applications are better suited for using conformal cooling channels alone on the injection mold core. This paper establishes injection molding models under different working conditions, simulates the cooling of dynamic mold temperature molds, and analyzes the effects of fluid media and various fluid rates on mold temperature changes. The results indicate that the cooling effect of cooling water is significantly better than that of cooling oil at the same fluid rate. When the fluid rate increases from 0.75 L/min to 6 L/min, the effect of cooling oil on the temperature change in the mold is significantly higher than that of cooling water. The influence of mold temperature on the cooling medium’s fluid rate tends to stabilize once the cooling medium’s flow rate reaches a specific value.