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<p>Excessive mold temperature differences, causing plastic part warpage deformation, have long plagued the injection molding industry. To solve this problem, this paper first optimizes the structure of the mold core conformal cooling channel. Combined with computational simulations, the influence of the mold temperature field is analyzed. Through simulations, the mechanism of temperature-induced warping during forming is revealed, addressing the issues of cooling efficiency and temperature uniformity in traditional designs. The optimized conformal cooling channel reduces the maximum warping deformation from 0.352 to 0.226&#xa0;mm, with the mold temperature difference decreased from 54.939 to 37.498&#xa0;°C. Using selective laser melting (SLM) technology and taking the flow rate (250 m<sup>3</sup>/h) as a key variable, material experiments demonstrate a sample density of 99.5%, surface roughness of 7.753&#xa0;μm, hardness of 382.8 HV, and compact uniform microstructure. This study also reveals the formation mechanisms of grain morphology governed by the G/R value (ratio of temperature gradient to solidification rate) and the generation mechanisms of forming defects induced by different types of spatter, providing theoretical support for SLM applications in mold manufacturing. Furthermore, the outcomes of this research establish a theoretical foundation and technical framework for the design and fabrication of injection molds with conformal cooling channels.</p>

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Optimization of conformal cooling channels in injection molds and investigation of SLM molding quality under flow rate gradients

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • Dongyu Liu,
  • Zeyu Yang,
  • Zhipeng Wu,
  • Jiajian Huang,
  • Yuhao Zeng,
  • Xin Shang

摘要

Excessive mold temperature differences, causing plastic part warpage deformation, have long plagued the injection molding industry. To solve this problem, this paper first optimizes the structure of the mold core conformal cooling channel. Combined with computational simulations, the influence of the mold temperature field is analyzed. Through simulations, the mechanism of temperature-induced warping during forming is revealed, addressing the issues of cooling efficiency and temperature uniformity in traditional designs. The optimized conformal cooling channel reduces the maximum warping deformation from 0.352 to 0.226 mm, with the mold temperature difference decreased from 54.939 to 37.498 °C. Using selective laser melting (SLM) technology and taking the flow rate (250 m3/h) as a key variable, material experiments demonstrate a sample density of 99.5%, surface roughness of 7.753 μm, hardness of 382.8 HV, and compact uniform microstructure. This study also reveals the formation mechanisms of grain morphology governed by the G/R value (ratio of temperature gradient to solidification rate) and the generation mechanisms of forming defects induced by different types of spatter, providing theoretical support for SLM applications in mold manufacturing. Furthermore, the outcomes of this research establish a theoretical foundation and technical framework for the design and fabrication of injection molds with conformal cooling channels.