Conformal Cooling Slots Welded Shut in Mould Cavity

Solution Overview

Problem

Conformal cooling passages in tools like moulds and dies are difficult to implement effectively due to high costs and poor approximation to the finished surface, especially in large tools such as those for vehicle bumpers, where intersecting passages are gun-drilled and plugged, leading to inefficiencies in cooling and cycle times.

Innovation Solution

Cut conformal cooling slots are machined into the tool cavity based on CAD data, welded shut with weld beads to create enclosed passages, and then machined to a class A surface matching the finished part shape, allowing for efficient and uniform cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If intersecting passages are gun-drilled and plugged to provide conformal cooling, then cooling passages can be provided in complex shaped tools, but the manufacturing cost increases and the approximation to the finished surface deteriorates

Engineering Contradiction:

Improveease of manufactureVSAvoidmanufacturing precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The cooling slots are cut into the rough mould cavity surface before the Class A finish is applied. This preliminary action allows the slots to be positioned accurately relative to the final surface geometry without requiring complex post-processing or gun-drilling operations after finishing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conformal cooling passages are created as separate slot features that are cut into the mould cavity surface, then enclosed by welding. This segmentation allows each cooling passage to be independently positioned and shaped according to the CAD data, improving precision while maintaining manufacturing ease.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If conformal cooling slots are cut deep into the rough mould cavity surface, then conformal cooling passages can be provided, but the Class A surface finish is compromised

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidease of manufacture

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The cooling slots are cut into the rough mould cavity surface before the Class A finish is applied. This preliminary action allows the slots to be positioned accurately relative to the final surface geometry without requiring complex post-processing or gun-drilling operations after finishing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The Class A surface is applied over the welded enclosure of the cooling slots, creating a finished surface that copies the intended part geometry while hiding the underlying cooling passage structure. This allows the cooling slots to be positioned deep in the rough surface without compromising the final surface quality.

Inventive Principle:

Principle #26Copying

3Productivity

If conformal cooling is implemented to improve cooling uniformity, then cooling efficiency improves, but the manufacturing complexity and cost increase

Engineering Contradiction:

ImproveproductivityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The cooling slots are cut into the rough mould cavity surface before the Class A finish is applied. This preliminary action allows the slots to be positioned accurately relative to the final surface geometry without requiring complex post-processing or gun-drilling operations after finishing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting of cooling slots and the application of Class A finish are merged into a sequential process where slot cutting precedes finishing. The welding of enclosure material over the slots integrates the cooling passage creation with the surface finishing operation, reducing overall manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method provides a cost-effective and accurate implementation of conformal cooling, improving cooling efficiency and reducing cycle times by creating precise, enclosed cooling passages that conform to the tool's complex surface, enhancing the cooling process in moulding and forming processes.

Implementation Method 1

The conformal cooling slots are enclosed by weld beads to provide sealed cooling passages

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The moulds are cooled during injection moulding to cool the plastic part

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

providing more uniform cooling of a part in a tool

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10625454B2Tool with conformal cooling

Publication Date: 2020.04.21 DR ARIEL ANDRE WAITZMAN

AI summary

A method of providing a tool with a conformal cooling passage includes rough machining a cavity generally corresponding to a manufactured part shape using CAD data. Conformal cooling slots are cut in the cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished manufactured part shape using the CAD data.