Develop Energy Usage Data of Various Molds Designs During Heating Cycles

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There are always some problems on the parts produced by conventional injection method, such as weld mark,flow mark, and other poor surface appearance. As a result, the mechanical properties and appearance of theplastic parts usually cannot meet the requirements of customers. The subsequent reprocessing operations haveto be employed in order to improve the part's properties. These operations increase the manufacturing processesof parts and waste raw material and energy. What is worse, they also increase the production cost and causeenvironment pollution inevitably. A novel polymer injection molding method has been developed. It canproduce high-quality plastic parts with excellent appearance and no weld marks. The subsequentprocesses-spraying and coating which seriously pollute the environment-can be eliminated. The energy,material, and production cost are decreased as well. In order to improve the cost-efficiency and part qualityfurther, the thermal response and heating/cooling efficiency of the temperature control system and the moldwas identified. The parameters of heating medium and coolant and mold thermal conductivity weresystematically investigated. With the progress of advanced manufacturing techniques, conformal coolingchannels used to improve cooling efficiency and uniformity in the mold were designed and fabricated. Themold structure and the lifetime of the mold were also investigated in order to reduce the consumption of theenergy and improve the production efficiency and part quality.