Hanzlik Jan, Vanek Jiri, Pata Vladimir, Senkerik Vojtech, Polaskova Martina, Kruzelak Jan, Bednarik Martin
Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic.
Faculty of Chemical and Food Technology, Slovak University of Technology in Bratislava, Radlinskeho 9, 812 37 Bratislava, Slovakia.
Materials (Basel). 2024 May 21;17(11):2477. doi: 10.3390/ma17112477.
Injection molding technology is widely utilized across various industries for its ability to fabricate complex-shaped components with exceptional dimensional accuracy. However, challenges related to injection quality often arise, necessitating innovative approaches for improvement. This study investigates the influence of surface roughness on the efficiency of conformal cooling channels produced using additive manufacturing technologies, specifically Direct Metal Laser Sintering (DMLS) and Atomic Diffusion Additive Manufacturing (ADAM). Through a combination of experimental measurements, including surface roughness analysis, scanning electron microscopy, and cooling system flow analysis, this study elucidates the impact of surface roughness on coolant flow dynamics and pressure distribution within the cooling channels. The results reveal significant differences in surface roughness between DMLS and ADAM technologies, with corresponding effects on coolant flow behavior. Following that fact, this study shows that when cooling channels' surface roughness is lowered up to 90%, the reduction in coolant media pressure is lowered by 0.033 MPa. Regression models are developed to quantitatively describe the relationship between surface roughness and key parameters, such as coolant pressure, Reynolds number, and flow velocity. Practical implications for the optimization of injection molding cooling systems are discussed, highlighting the importance of informed decision making in technology selection and post-processing techniques. Overall, this research contributes to a deeper understanding of the role of surface roughness in injection molding processes and provides valuable insights for enhancing cooling system efficiency and product quality.
注塑成型技术因其能够制造出具有出色尺寸精度的复杂形状部件而在各个行业中得到广泛应用。然而，与注塑质量相关的挑战经常出现，这就需要创新方法来加以改进。本研究调查了表面粗糙度对使用增材制造技术（特别是直接金属激光烧结（DMLS）和原子扩散增材制造（ADAM））生产的随形冷却通道效率的影响。通过结合实验测量，包括表面粗糙度分析、扫描电子显微镜和冷却系统流动分析，本研究阐明了表面粗糙度对冷却通道内冷却剂流动动力学和压力分布的影响。结果显示，DMLS和ADAM技术在表面粗糙度上存在显著差异，并对冷却剂流动行为产生相应影响。基于这一事实，本研究表明，当冷却通道的表面粗糙度降低高达90%时，冷却剂介质压力的降低幅度为0.033 MPa。开发了回归模型以定量描述表面粗糙度与关键参数（如冷却剂压力、雷诺数和流速）之间的关系。讨论了注塑成型冷却系统优化的实际意义，强调了在技术选择和后处理技术中进行明智决策的重要性。总体而言，本研究有助于更深入地理解表面粗糙度在注塑成型过程中的作用，并为提高冷却系统效率和产品质量提供了有价值的见解。
