Cooling Channel Component Build With Machined Connecting Cavities
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Solution Overview
Problem
Conventional methods for producing components with cooling channel systems face challenges in efficiently cooling complex geometries due to limitations in inserting internal cooling channels, leading to suboptimal heat dissipation and potential mechanical weaknesses.
Innovation Solution
A hybrid manufacturing process combining additive fabrication and material removal techniques to create a cooling channel system with connecting channels that adapt to complex geometries, allowing for improved heat dissipation and surface quality by forming channels that follow the external contours of the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are introduced into the finished tool by drilling, then the tool can be cooled, but the geometric complexity of the tool limits the effectiveness of the cooling channels
Solution Approach 1:
The cooling channels are formed during the additive manufacturing process itself, before the tool is completed. This preliminary action allows the cooling channel geometry to be integrated with the final tool shape, enabling complex cooling paths that adapt to the tool's geometric complexity rather than being limited by post-manufacturing drilling constraints
Solution Approach 2:
The invention changes the manufacturing parameter from conventional drilling to additive manufacturing, which enables the creation of cooling channels with complex geometries that match the tool's shape. This parameter change allows cooling channels to be formed with precise control over their path, diameter, and orientation, optimizing cooling effectiveness for complex tool geometries
2Shape
If additive manufacturing is used to create cooling channels during construction, then complex geometries can be achieved, but the heat dissipation capability is limited
Solution Approach 1:
The cooling channel system is segmented into multiple sections that can be independently optimized. The invention divides the cooling channel into different zones with varying geometries, allowing each section to be tailored for optimal heat dissipation in different areas of the tool, thereby improving overall thermal management while maintaining geometric complexity
Solution Approach 2:
The invention employs composite construction by combining additive manufacturing with other processes (such as infiltration or hybrid manufacturing) to create cooling channels with enhanced thermal conductivity. This composite approach allows the cooling channels to achieve both complex geometries and superior heat dissipation capabilities by integrating materials or structures that improve thermal transfer
3Ease of manufacture
If conventional drilling is used to create cooling channels, then the manufacturing process is simple, but the cooling channels cannot adapt to complex component geometries
Solution Approach 1:
The invention replaces the mechanical drilling process with additive manufacturing technology. This substitution eliminates the limitations of drill bit access and geometry constraints, allowing cooling channels to be built layer-by-layer to precisely match complex component surfaces and internal structures, thereby achieving high adaptability while maintaining manufacturing efficiency
4Strength
If cooling channels are added after tool completion, then the tool structure remains intact, but the cooling channels create mechanical weaknesses
Solution Approach 1:
The invention merges the cooling channel formation with the tool manufacturing process itself. By integrating cooling channel creation into the additive manufacturing process, the cooling channels become an intrinsic part of the tool structure rather than separate features added later. This merging eliminates weak points associated with post-manufacturing modifications and ensures uniform material properties throughout the tool, including the cooling channels
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 approach enhances heat dissipation rates, reduces flow resistance, and improves the mechanical integrity of components with complex geometries, enabling faster cooling and increased durability.
Implementation Method 1
building up a first section of the component by additively applying a build-up material
Implementation Method 2
For heat dissipation, cooling channels are usually provided within the mold insert or injection molding tool, through which a suitable coolant flows
Implementation Method 3
a liquefied material is injected under pressure into a mold insert or injection molding tool, cools down there and returns to a solid state
Data Source
Figure 1a~1c
Figure 1d~1e
Figure 1f
AI summary
The invention provides a method for producing a component (100) having a cooling channel system, the method comprising: - building a first portion (10) of the component (100) by means of the additive, integrally bonded application of a build material; and - introducing a first cavity (11) having an opening into the first portion (10) of the component (100). The method is characterized in that it also comprises: - covering the opening of the first cavity (11) in the first portion (10) by means of a covering part (13); - building a second portion (20) of the component (100) by means of the additive, integrally bonded application of the build material, the build material being applied to the first portion (10) and to the covering part (13); - introducing a second cavity (21) having an opening into the second portion (20) of the component (100); and - introducing a connecting channel (90), (90a) into the component (100) by means of material-removing machining in order to form the cooling channel system, the connecting channel (90), (90a) connecting the second cavity (21) of the second portion (20) to the first cavity (11) of the first portion (10) of the component (100).