The paper presents a hybrid cooling model based on the use of newly designed fluted conformal cooling channels in combination with inserts manufactured with Fastcool material. The hybrid cooling design was applied to an industrial part with complex geometry, high rates of thickness, and deep internal concavities. The geometry of the industrial part, besides the ejection system requirements of the mold, makes it impossible to cool it adequately using traditional or conformal standard methods. The addition of helical flutes in the circular conformal cooling channel surfaces generates a high number of vortexes and turbulences in the coolant flow, fostering the thermal exchange between the flow and the plastic part. The use of a Fastcool insert allows an optimal transfer of the heat flow in the slender core of the plastic part. An additional conformal cooling channel layout was required, not for the cooling of the plastic part, but for cooling the Fastcool insert, improving the thermal exchange between the Fastcool insert and the coolant flow. In this way, it is possible to maintain a constant heat exchange throughout the manufacturing cycle of the plastic part. A transient numerical analysis validated the improvements of the hybrid design presented, obtaining reductions in cycle time for the analyzed part by 27.442% in comparison with traditional cooling systems. The design of the 1 mm helical fluted conformal cooling channels and the use of the Fastcool insert cooled by a conformal cooling channel improves by 4334.9% the thermal exchange between the cooling elements and the plastic part. Additionally, it improves by 51.666% the uniformity and the gradient of the temperature map in comparison with the traditional cooling solution. The results obtained in this paper are in line with the sustainability criteria of green molds, centered on reducing the cycle time and improving the quality of the complex molded parts.
Keywords: conformal cooling; green channels; industrial design; injection molding; numerical simulation; sustainability; temperature maps.