Lq. Tang et al., A COMPUTER-AIDED OPTIMIZATION APPROACH FOR THE DESIGN OF INJECTION MOLD COOLING SYSTEMS, Journal of mechnical design, 120(2), 1998, pp. 165-174
A methodology is presented for the design of optimal cooling systems f
or injection mold tooling which models the mold cooling as a nonlinear
constrained optimization problem. The design constraints and objectiv
e function are evaluated using Finite Element Analysis (FEA). The obje
ctive function for the constrained optimization problem is stated as m
inimization of both a function related to part average temperature and
temperature gradients throughout the polymeric part. The goal of this
minimization problem is to achieve reduction of undesired defects as
sink marks, differential shrinkage, thermal residual stress built-up,
and part warpage primarily due to non-uniform temperature distribution
in the part. The cooling channel size, locations, and coolant flow ra
te are chosen as the design variables. The constrained optimal design
problem is solved using Powell's conjugate direction method using pena
lty function. The cooling cycle time and temperature gradients are eva
luated using transient heat conduction simulation. A matrix-free algor
ithm of the Galerkin Finite Element Method (FEM) with the Jacobi Conju
gate Gradient (JCG) scheme is utilized to perform the cooling simulati
on. The optimal design methodology is illustrated using a case study.