Sensitivity analysis of conformal cooling channels for injection molds: 2D Transient Heat Transfer Analysis

The fabrication of conformal cooling channels (CCCs) has become increasingly efficient and cost-effective throughout the past few years. Conformal cooling channels, also known as CCCs, are superior to straight-drilled channels in terms of efficiency in injection molding engineering applications owing to their ability to provide superior cooling. The ability of CCCs to conform to the curves of molded geometry is the reason for this. The implementation of CCCs results in a significant reduction in the amount of time required for cooling, total injection time, thermal stresses, and warpage. Compared to the construction of a regular channel, the construction of a CCC is usually more complex. To maximize the development of designs that are both economically viable and highly efficient, computer-aided engineering (CAE) simulations are necessary. The purpose of this study is to conduct a sensitivity analysis of a full injection mold, with eight cooling channels, by means of a thermal analysis performed in 2D. The objective is to achieve the best possible placement of CCCs to diminish the amount of time required for ejection and to enhance the uniformity of temperature distribution. The results show that all the variables have significant sensitivity to the maximum and average temperature on the injected part and, therefore, are suitable for design optimization procedures.