Optimisation of Continuous and Pulsed Cooling in Injection Moulding Processes

Abstract

The concept of pulsed cooling in injection moulding involves cycling the flow of coolant in order that cooling only takes place as and when it is required, as opposed to continuous cooling, where the coolant in run through the channels throughout the entire process. It is claimed that using the pulsed cooling method, with reduced temperature coolants, may reduce cycle times and overall energy consumption for the injection moulding process, when compared with continuous cooling. It is also suggested that this is not at the expense of component integrity since common defects such as warpage, which could come about due to non-uniform cooling of the component, or impedance of flow of the polymer into the mould cavity during injection, do not normally appear.

The study described in this paper uses a previously validated numerical model in order to optimise the cooling phase of the injection moulding process, for both continuous and pulsed cooling, in order to assess the advantages and disadvantages of each method, with respect to cycle times. In addition, the optimisations were carried out with a view to improving cycle times experimentally, taking into consideration the findings of the study.