Week 9 Challenge

Objective

Run a cool analysis on the ruler geometry. Compare the result of the cool analysis by using a normal cooling circuit and a chiller circuit and also check the deflection based on the choice of cooling circuit.

Procedure

Following are the process to get the result:

1. Create a normal cooling circuit and chiller circuit:

Details of normal cooling circuit:

Method of creation	Manual
Cross section	Circular
Diameter	6mm

Details of chiller circuit:

Method of creation	Manual
Cross section	Circular
Diameter	6mm
Chiller property type	channel
Chiller material	Beryllium cooper
Chiller diameter	8mm

Fig: normal cooling circuit.

Fig: chiller circuit

2. Set analysis sequence to “cool+fill+pack+warp”.

2. Select material as “valox 365”.

2. Set injection location for coolant flow:

Fig: coolant inlet of normal cooling circuit

Fig: coolant inlet and outlet of chiller circuit

5. Select coolant as “oil”.
6. Process setting:

Details:

Melt temperature	301°C
Mold open time	3 second
Injection+packing+cooling time	12 second
Filling control	Injection time = 0.7 second
Volume/pressure switch control	By %volume filled = 98%
Pack/holding control	%filling pressure vs time: Duration %filling pressure 0.2 80 3 80 1 60

7. Run the analysis:

cool and deflection results:

Cool analysis results	Normal cooling circuit values	Chiller circuit values
Circuit coolant temperature	25°c	25°c
Circuit flow rate	1971.7 lit/min	2629.0 lit/min
Circuit Reynold number	10000	13333
Circuit metal temperature	27.99°c	40.92°c
Temperature at surface, cold runner	50.24°c	49.79°c
Time to reach ejection temperature, part	22.51 sec	22.50 sec
Time to reach ejection temperature, cold runner	23.10 sec	23.36 sec
Temperature, maximum, part	207.5°c	207.6°c
Temperature, maximum, cold runner	225°c	226.8°c
Average temperature, part	152.6°c	152.7°c
Average temperature, cold runner	170.5°c	171.4°c
Temperature profile, part	207.5	207.6
Temperature profile, cold runner	225	226.8
Circuit minor loss coefficient	1.056	2.022
Circuit friction factor	0.0423	64
Temperature, mold	57.20°c	57.56°c
Temperature, part	71.92°c	72.24°c
Flux, part	48486 w/m²	48469 w/m²
Deflection, all effects	3.217 mm	3.181 mm

Learning outcomes

Following are the things that I have learned in this challenge are:

1. Cooling insert are used in a place were channels are incapable to produce cooling.
2. Channels can made by manual meshing method or manual beam creation method.
3. Orientation defects are diagnosed by “orient all” feature.
4. Solution for “error 702281” is to indicate the coolant outlets.
5. Solution for “error 702310” is to change the property type of the element.
6. According to my observation on the part with chiller circuit and with normal cooling circuit it was found that part with chiller circuit is better, following are the reasons:

• It tends to give high circuit flow rate.
• Circuit absorbs more amount of heat from the part.
• It helps in providing lower deflection to the part.

Conclusion

The challenge was somehow tricky in finding the better circuit for the part. And also, it helps me in performing result interpretation. The whole process gives me the feeling of real life designing of the part. The main thing which I like in this challenge is use of chiller circuit. Thanks to skill-lync for helping me in completing this.