COOL ANALYSIS OF RULER GEOMETRY

1 INTRODUCTION

The cool analysis in the MOLDFLOWgives significant results. It helps the analyst to check the part deflections and other inaccuracies that occurred in part. By this data, the analyst can improve the cooling circuit design accordingly to the model.

2 OBJECTIVE

The objective of the current challenge is to do cool analysis using normal circuits and chiller circuits. The results between them are compared, and the best circuit for the model is studied.

3 PROCEDURE

STEP 1: Create the ruler geometry using the geometry tools in the tools menu bar.

Figure 1: Creation of ruler geometry.

STEP 2: Mesh the model using the dual-domain mesh with a global edge length of 1 mm.

Figure 2: Generating the dual-domain mesh.

STEP 3: Check for free edges, non-manifold edges, the orientation of the elements, overlap of the elements.

STEP 4: Set the material as Valox 365 from the material options in the study panel.

Figure 3: Properties of Valox 365 material

STEP 5: Set the analysis as gate location and start the analysis. The MOLDFLOW automatically sets predefined best gate location for the model.

Figure 4: Setting the gate location.

STEP 6: Create the runner system for the model.

Figure 5:Creating the runner system.

STEP 7: Create channel circuits with geometrical properties as circular, non-tapered, and diameter 6 mm on the top and bottom of the model.

Figure 6: Creating the coolant circuits.

STEP 8: Set the coolant inlet and change the coolant type as oil and temperature as 60˚C.

Figure 7: Setting coolant as oil and coolant inlet temperature as 60˚C.

STEP 9: Change the process settings as per the required conditions.

Figure 8: Changing the process temperature according to the required conditions.

STEP 10: Start the cool+fill+pack+warp analysis.

STEP 11: Duplicate the study and input the chiller circuit. Select one of the coolant inlets and change the coolant inlet temperature to 15˚C.

Figure 9: Creating chiller circuit by decreasing the coolant inlet temperature to 15˚C.

4 RESULTS AND DISCUSSION

The deflection results obtained between the normal cooling circuit and the chiller circuit are compared. It seems that the normal cooling circuit has lower deflection values than the chiller circuit. The highest deflection in the normal circuit is 2.99 mm, and in the chiller circuit is 3.00 mm shown in Figure 10. The deflection is mainly in the z-direction as shown in Figure 11; the finished part may have some curve rather than straight.

Figure 10: Comparision of deflections, all effects in normal and chiller cooling circuits.

Figure 11: Maximum deflection in z-direction.

The cause of deflection is being checked, and it seems as the deflection due to differential cooling is 0.0103 mm in normal coolling circuit and 0.2357 mm in chiller circuit as shown in Figure 12. The deflection in normal circuit is small and negligable but in chiller circuit it has to be taken care.

Figure 12: Deflections due to differential cooling.

Still, the deflection due to differential shrinkage is high, which causes the part to deflect. The normal circuit has 2.995 mm deflection where as chiller circuit has 3.145 mm as shown in Figure 13. This is mainly because of the selected material. The deflection due to differential shrinkage can be overcome by making the model over packed.

Figure 13: Deflections due to differential shrinkage.

There is no orientation deflection in both the circuits.

Figure 14: Deflection due to orientation effect.

To overcome the deflection due to shrinkage, the overpacked process settings are provided to check whether the deflection decreases or not.

Figure 15: Overpacked process settings.

The deflection due to shrinkage in overpacked setting analysis is 3.863 mm which is higher than the normal and chiler circuits. So it is not recommende to use the overpacked settings for the current geometry.

Figure 16: Deflection due to shrinkage in overpacked analysis.

5 CONCLUSION

From the cool+fill+pack+warp analysis on the ruler geometry using the Valox 365 material and coolant as oil with normal and chiller circuits, it is observed that the normal circuit is better than the chiller circuit. It is also observed that the material selected does not apply to current geometry, in the change of material, the differential shrinkage deflections may decrease.

DRIVE LINK: https://drive.google.com/drive/folders/1IQoRdCHB1HtXlKfJE5CILy8FenQ-gYMA?usp=sharing