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Eliette Mathey
Abstract
Injection mould cooling optimization using boundary element heat transfer simulation
Eliette Mathey - 17 december 2004
Part quality and cycle time during injection moulding depend on heat transfer within the mould and the polymer part. Numerical simulation methods are widely used as an help to mould cooling conception. In this work, an optimization procedure of the cooling system is proposed. This procedure is based on numerical simulation of the cooling stage using the boundary element method.
Heat transfer during injection are simulated using two models : a stationary model, solved by the boundary element method, gives access to mean mould temperatures. The dual reciprocity method is used to solve the transient model to obtain temperature variations in the mould and the polymer part during the cooling phase. These two methods have been programmed and validated by comparison with analytical solutions.
Numerical simulation is then used in an optimization loop to find the best combination of cooling system greometry and coolant parameters. A study of the possible parameters, objective functions, constraint handling techniques is carried out. Optimization is performed with a sequential quadratic programming method and uses derivative of the objective function according to optimization parameters. Sensitivity analysis can be performed by a finite difference method or by direct differentiation of the boundary integral equation.
The optimization procedure is applied to 2D mould sections to study the effects of the objective function, the constraints and the simulation models used. Simulation results are also compared to experimental measures of mould temperatures during injection.
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