Examinando por Autor "Torres-Alba, Abelardo"

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A New Conformal Cooling Design Procedure for Injection Molding Based on Temperature Clusters and Multidimensional Discrete Models
(MDPI, 2020-01-07) Torres-Alba, Abelardo; Mercado-Colmenero, Jorge Manuel; Díaz-Perete, Daniel; Martín-Doñate, Cristina
This paper presents a new method for the automated design of the conformal cooling system for injection molding technology based on a discrete multidimensional model of the plastic part. The algorithm surpasses the current state of the art since it uses as input variables firstly the discrete map of temperatures of the melt plastic flow at the end of the filling phase, and secondly a set of geometrical parameters extracted from the discrete mesh together with technological and functional requirements of cooling in injection molds. In the first phase, the algorithm groups and classifies the discrete temperature of the nodes at the end of the filling phase in geometrical areas called temperature clusters. The topological and rheological information of the clusters along with the geometrical and manufacturing information of the surface mesh remains stored in a multidimensional discrete model of the plastic part. Taking advantage of using genetic evolutionary algorithms and by applying a physical model linked to the cluster specifications the proposed algorithm automatically designs and dimensions all the parameters required for the conformal cooling system. The method presented improves on any conventional cooling system design model since the cooling times obtained are analogous to the cooling times of analytical models, including boundary conditions and ideal solutions not exceeding 5% of relative error in the cases analyzed. The final quality of the plastic parts after the cooling phase meets the minimum criteria and requirements established by the injection industry. As an additional advantage the proposed algorithm allows the validation and dimensioning of the injection mold cooling system automatically, without requiring experienced mold designers with extensive skills in manual computing.
A New Conformal Cooling System for Plastic Collimators Based on the Use of Complex Geometries and Optimization of Temperature Profiles
(MDPI, 2021-08-16) Mercado-Colmenero, Jorge Manuel; Torres-Alba, Abelardo; Catalán-Requena, Javier; Martín-Doñate, Cristina
The paper presents a new design of conformal cooling channels, for application in collimator-type optical plastic parts. The conformal channels that are presented exceed the thermal and dynamic performance of traditional and standard conformal channels, since they implement new sections of complex topology, capable of meeting the high geometric and functional specifications of the optical part, as well as the technological requirements of the additive manufacturing of the mold cavities. In order to evaluate the improvement and efficiency of the thermal performance of the solution presented, a transient numerical analysis of the cooling phase has been carried out, comparing the traditional cooling with the new geometry that is proposed. The evolution of the temperature profile versus the thickness of the part in the collimating core with greater thickness and temperature, has been evaluated in a transient mode. The analysis of the thermal profiles, the calculation of the integral mean ejection temperature at each time of the transient analysis, and the use of the Fourier formula, show great improvement in the cycle time in comparison with the traditional cooling. The application of the new conformal design reduces the manufacturing cycle time of the collimator part by 10 s, with this value being 13% of the total manufacturing cycle of the plastic part. As a further improvement, the use of the new cooling system reduces the amount of thickness in the collimator core, which is above the ejection temperature of the plastic material. The improvement in the thermal performance of the design of the parametric cooling channels that are presented not only has a significant reduction in the cycle time, but also improves the uniformity in the temperature map of the collimating part surface, the displacement field, and the stresses that are associated with the temperature gradient on the surface of the optical part.
Application of new conformal cooling layouts to the green injection molding of complex slender polymeric parts with high dimensional specifications
(MDPI, 2023-01-21) Torres-Alba, Abelardo; Mercado-Colmenero, Jorge Manuel; Caballero-Garcia, Juan de Dios; Martin-Doñate, Cristina
Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric features, as occurs with topologies of great length and slenderness with high changes in thickness. These features are, in these special geometries, impossible to manufacture with traditional technologies meeting the dimensional and sustainable requirements of the industry. The paper presents an innovative green conformal cooling system that is specifically designed for parts with slender geometric shapes, highly susceptible to warping. Additionally, the work presented by the authors investigates the importance of using highly conductive inserts made of steel alloys in combination with the use of additively manufactured conformal channels in reducing influential parameters such as warpage, cooling time and residual stresses in the complex manufacturing of long and slender parts. The results for a real industrial case study indicate that the use of conformal cooling layouts decreases cycle time by 175.1 s - 66% below the current cooling time, the temperature gradient by 78.5% specifically 18.16 ºC, the residual stress by 39.78 MPa or – 81.88 %, and the warpage by 6.9 mm or- 90.5%. In this way, it is possible to achieve a final warping in the complex geometry studied of 0.72 mm under the maximum value required at the industrial level of 1 mm. The resulting values obtained by the researchers present a turning point from which the manufacturing and sustainability in injection molding of said plastic geometries is possible, taking into account that the geometric manufacturing features 30 analyzed, will present a great demand in the coming years in the auto parts manufacturing industry
Methodology for intelligent plastic injection point location based on geometric algorithms and discrete topologies for virtual digital twin environments
(FEDERACION ASOCIACIONES INGENIEROS INDUSTRIALES ESPANAALAMEDA DE MAZARREDO, BILBAO 69-48009, SPAIN, 2014-01) Mercado-Colmenero, Jorge Manuel; Torres-Alba, Abelardo; Martin-Doñate, Cristina
Implementing intelligent design models can revolutionize the use of digital twins, which are crucial in product design by incorporating intelligent algorithms. This perspective is especially important for the design of injection-molded plastic parts, a complex process that often requires expert knowledge and costly simulation software not available to all companies. This article presents an innovative methodology for locating injection points in injection-molded parts using intelligent models with geometric algorithms for discrete topologies. The first algorithm calculates the center of mass of the discrete model based on the center of mass of each triangular facet in the system, ensuring uniform molten plastic distribution during mold cavity filling. Two sub-algorithms intelligently evaluate the geometry and optimal injection point location. The first sub-algorithm generates a geometric matrix based on a two-dimensional nodal quadrature adapted to the part's bounding box. The second sub-algorithm projects the nodal matrix and associated circular areas orthogonally on the part's surface along the demolding direction. The optimal injection point location is determined by minimizing the distance to the center of mass from the first algorithm's result. This novel methodology has been validated through rheological simulations in six case studies with complex geometries. The results demonstrate uniform and homogeneous molten plastic distribution with minimal pressure loss during the filling phase. Importantly, this methodology does not require expert intervention, reducing time and costs associated with manual injection mold feed system design. It is also adaptable to various design environments and virtual twin systems, not tied to specific CAD software. The validated results surpass the state of the art, offering an agile alternative for digital twin applications in new product design environments, reducing dependence on experts, facilitating designer training, and ultimately cutting costs

RUJA: Repositorio Institucional de Producción Científica

Examinando por Autor "Torres-Alba, Abelardo"