* The objective of this work is to predict the temperature distribution on die using ANSYS. * To optimize the cooling time by changing the cooling channel position. * To find out the best cooling channel form. *To investigate the effect of thermal residual stresses in injection molding die.

1. Influence of Cooling Channel Position and Cooling
Channel Form on Polymer Temperature and
Solidification on Injection Molding Die Using Finite
Element Method.
GUIDED BY
Mr.T.PREM SINGH INBARAJ, M.E,
SUBMITTED BY
KARTHIKEYAN.S (97408114025)
SAM PRATHAP SINGH.P (97408114700)
SARAVANA KUMAR.C.M (97408114304)

2. INTRODUCTION
 Injection molding is the most commonly used
manufacturing process for the fabrication of plastic parts.
 A wide variety of products are manufactured using
injection molding, which vary greatly in their size,
complexity, and application.
 The plastic is melted in the injection molding machine and
then injected into the mold, where it cools and solidifies
into the final part.

3. Process Cycle

4. Objective
 The objective of this work is to predict the temperature
distribution on die.
 To optimize the cooling time by changing the cooling
channel position.
 To find out the best cooling channel form.
 To investigate the effect of thermal residual stresses in
injection molding die.

5. METHODOLOGY

6. Selection of Component
Dimension of the component are
Base diameter of the cup - 50 mm
Thickness of the cup - 5 mm
Height of the cup -40 mm

7. Cooling Channel Position

8.  To simplify the analysis, symmetry of the component
is selected. Totally eleven cooling channel are selected
for the analysis.
 Four rows and one column are analyzed. A, B, C and D
represents the rows and E represents the column. A, B,
C and D contains the two cooling channel in each row
and column E contains three cooling channels.

9.  Two cooling channels are selected from the top
position, so that six positions are available from the
top.
 For every fixed top position there is a change in
bottom and side position of cooling channels. Totally
108 positions are found for the analysis.
 The element selected for the 2D transient thermal
analysis is PLANE 55 2D 4 node quadrilateral thermal
solid element.

10. Material Properties
The material used for die and component are stainless steel
and ABS plastics.

11. The assumptions made for carrying out the
transient thermal analysis are as follows.
 Material is isotropic.
 Material for die and component are different.
 The thermal conductivity, density and specific heat for
die and component are temperature independent.

12. The boundary conditions applied in the model are as
follows
.
 The uniform temperature of 30o C & 120o C are
applied to the die and component.
 Convection load applied to the die surface and
cooling channel surface.

13. The loads and boundary conditions in various parts of spindle are as
follows
Initial condition
 Die
 Component
Convection
 Die outer surface
 Cooling channel surface
 Define the load step options and substeps.
 Solve the load step.
 Review the results from time history post processor section.

14. Steps in Transient Thermal Analysis
The steps to do the transient thermal analysis of
spindle are as follows
 Develop the model and define the material properties.
 Mesh generation.
 Define new analysis as transient analysis
 Apply the loads and boundary conditions.

15. Temperature distribution for position B1B2C2D2E2E3 at 15 sec

16. Temperature distribution for position A2B2C1C2E2E3 at 15 sec

17. Temperature decreasing rate of various positions over time
350
355
360
365
370
375
380
385
390
395
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A2B2C1C2E2E3
A1B2D1D2E2E3
A1B2C2D2E1E3
A1B1C2D2E2E3
Time (sec)
Temperature(sec)

18. Temperature Distribution Results for Form of equal cross
sectional area
Circular cooling channel

19. Square cooling channel

20. Rectangular cooling channel

21. The temperature decreasing rate of different cooling channel form
have equal cross sectional area for particular position
A2B2C1C2E2E3
350
355
360
365
370
375
380
385
390
395
0 2 4 6 8 10 12 14 16
CIRCULAR CHANNEL
SQUARE CHANNEL
RECTANGULAR CHANNEL
Time(sec)
Temperature(k)

22. Temperature distribution for different form of cooling channel
have equal perimeter at position A2B2C1C2E2E3 at 15 seconds

23. Rectangular cooling channel

24. Square cooling channel

25. The temperature decreasing rate of different cooling channel form
have equal perimeter
350
355
360
365
370
375
380
385
390
395
0 2 4 6 8 10 12 14 16
CIRCULAR CHANNEL
SQUARE CHANNEL
RECTANGULAR CHANNEL
Time(sec)
Temperature(k)

26. Thermal stress

27. Conclusion
 .From the position analysis it is found that
A2B2C1C2E2E3 is more effective when compared with
all other positions of the cooling channels.
 In form of cooling channel circular cooling channel
is more effective when compared to rectangular and
square cooling channel.

28. References
1. Handy Hassan, Nicolas Regnier, Cedric Lebot, Cyril
Pujos, Guy Defaye, ”Effect of cooling system on the
polymer temperature and solidification during
injection molding”, Journal of applied thermal
engineering.
2. Li Q. Tang, Constanian chassapis, Souran
manoochehri, “Optimal Cooling System Design for
Multi-cavity Injection Molding.
3. A text book of “Heat Transfer, A Practical Approach” by
Yunus A.Cengel, McGraw-Hill series in mechanical
engineering (2nd ed.).