Numerical analysis of hot and cold spots defects in Rapid Heat Cycle Molding

process
Fatma KRIAa, Moez HAMMAMIb, Mounir BACCARc.
a
Computational Fluid Dynamic and Transfer Phenomena, Mechanical Engineering, Tunisia, Sfax,
fatmakria1984@yahoo.fr
b
Computational Fluid Dynamic and Transfer Phenomena, Mechanical Engineering, Tunisia, Sfax,
hammamimoez2003@yahoo.fr
c
Computational Fluid Dynamic and Transfer Phenomena, Mechanical Engineering, Tunisia, Sfax,
mounir.baccar@enis.rnu.tn
Abstract – The purpose of this numerical study is to predict the molding defects and suggest solutions to remedy
these problems. For this purpose, a fine and precise study of heating/cooling cycles of Rapid Heat Cycle Molding
(RHCM) producing LCD panels is undertaken. Heat transfers in mold and cavity are predicted by the commercial
software analysis Fluent 6.3 in cyclic transient regime. It was found that, for the first proposed geometry of the LCD
panel with sharp corners, there is appearance of hot and cold spots. The detected defects affects the quality of the
finished product by causing shrinkage and productivity by slowing the cooling phase.To remedies these problems, a
modification of the shape of the LCD panel is provided. In fact, by rounding inside and outside sharp corners, it was
demonstrated a reduction in the cycle time, the temperature gap and the quantity of consumed energy. Therefore, the
proposed solution improves the quality of the LCD panel and the productivity of the process.

Keywords: Rapid Heat Cycle Molding / Molding defects / Hot spots / Cold spots / Numerical
simulation.

Hammamet, 23-25 March 2015, Tunisia 1

The 6th International Congress Design and Modelling of Mechanical Systems CMSM’2015
1 Introduction
Rapid Heat Cycle Molding (RHCM) process is a
new technique in the field of thermoplastic
injection. RHCM includes over the cooling phase,
the heating phase at a temperature slightly higher
than the glass transition temperature of the injected
polymer. With this technique, it has been
demonstrated [1-3] that it was possible to remedy
several defects namely the weld lines, flow marks
and faulty surfaces.
On the other hand, several researches focused on
the design of thermal regulation system of the
RHCM process. In fact, they [4, 5] have suggested
a 2D study to optimize the heating/cooling channels
design. They [5] have founded that when the
spacing between the channels is important and the
distance between the channels and cavity is small,
heating is more efficient. In addition, the
distribution channels with a low spacing and far
from cavity surface promotes temperature
homogeneity at the cavity surface. Also, [6] found
that the increase of the distance between the heating
channels, was done on the one hand, a gain of
54.5% on the homogeneity of the temperature
distribution on the cavity surface and on the other
hand, a decrease in the heating rate.
Most previous studies have focused on the
optimization of the heating/cooling channels
design. However, these research works are in 2D
developing only the first heating phase. The
exploitation of the results after cooling phase is not
yet investigated. For this, this work takes into
account, in addition to the heating phase, the
cooling phase. Indeed, the prediction of the
temperature distribution at the studied part is
critical for predicting the possibility of the
appearance of molding defects. This study is
interested in the thermal regulation of RHCM
producing LCD panel. A modification of the shape
of the LCD panel is intended to remedy the
molding defects namely hot and cold spots.
2 Mathematical formulation
The heat transfer between the channels and the
mold can be taken into consideration by the thermal
transfer coefficient interface hc. In the heating
phase, the convective heat transfer coefficient is
given by the following expression:
1/ 4
 K 3  w ( w   S ) g r 
hc  0.555  
  D (Tvap  TP )  (1)
With:
K thermal conductivity of water at 100°C,
g acceleration of gravity,
Hammamet, 23-25 March 2015, Tunisia
r latent heat of liquefaction,
ρs density of saturated steam,
ρw density of water,
μ dynamic viscosity of water at 100°C,
D diameter of the heating channels,
Tvap temperature of the saturated steam,
TP temperature at the heating channel wall.
For the cooling phase, constant convective heat
transfer coefficient is adopted:
hr = 3500 W/m2K
2.1 Initial and boundary conditions
For the heating phase, the mold is initially at
ambient temperature (30°C). The temperature at the
heating channels is a constant of 180°C. The
cooling stage starts when the outer surface of the
cavity of the LCD panel is heated to a temperature
of 120°C. The polymer is injected into the mold
cavity at a temperature of 230°C and cooled by
water at 30°C. The polymer is cooled to a
temperature of 95°C considered sufficient to eject
the part without any significant deformation.
With regard to the boundary conditions, a zero heat
flux condition is used in the symmetry planes.
Besides, a zero heat flux condition is considered at
the exterior surface of the mold since an insulation
layer was added to limit the heat losses and
accelerate the heating phase.
The resolution of the energy equations is based on
the finite volume method using the commercial
software analysis Fluent6.3.
3 Results and discussion
3.1 First geometry of LCD panel
Figure one shows the geometry of the studied LCD
panel and the studied domain of the considered
RHCM mold. The considered part presents four
sharp corners.
Figure 1. First geometry proposed (P1) and studied
domain (quarter of the mold)
The simulation of the first three molding cycles
shows that a steady state is established from the
second cycle. However, for the cooling phase, the
2
The 6th International Congress Design and Modelling of Mechanical Systems CMSM’2015
thermal state is steady from the first cycle. The 20,52
3 25,032 P2 P1
numerical simulations have shown a rapid cooling

Cycle number
at outer sharp corners causing the appearance of 2 20,55
24,975
cold spots. For the inner sharp corners, cooling is
21,85
slow generating the appearance of hot spots. To 1 26,03
remedy these problems and avoid the appearance of
0 10 20 30
hot spots and cold spots, we must proceed to the Cooling time(s)
rounding of corners.
3 8,04
9,224
3.2 Modified geometry of LCD panel

Cycle number
P2 P1
2 8,13
9,215

Figure two shows the modified geometry of the 1 18,76

18,62
LCD panel. A rounding of sharp corners is
undertaken. 0 5 10 15
Heating time (s)
20

3 78,25
90

Cycle number
P2 P1
2 79,13
90,1

1 213,71
211,825

0 50 100 150 200 250

Consumed energy (KJ)

Figure 2. Second geometry proposed (P2) 3 4,54

5,37 P2
Cycle number

2 4,7 P1
5,33
Figures three and four compare the results obtained
for the two geometrical configurations P1 and P2 of 1 9,46
9,18
the LCD panel.
0 2 4 6 8 10
Temperature gap(°C)
160
Figure 4. Comparison of the two proposed shapes
Temperature (°C)

120 of the LCD panel (P1 and P2)

80
40 P1 P2
0 on surface appearance properties of the molded part
0 50 100
Time (s)
Figure 3. Temperature evolution of point B
Figure three presents the cyclic transient
temperature variations of point B with time for the
three first molding cycles. It has been noted that the
steady cycle is obtained rapidly (after two or three
cycles) for the RHCM process compared with
conventional injection molding (CIM).
The histograms of figure four compare the heating
time, cooling time, the temperature gap and the
consumed energy. The modified geometry of the
LCD panel P2 provides not only the disappearance
of hot spots, but promotes a significant reduction in
heating and cooling time. In fact, it provides a gain
of 18.22% at the cooling time and 10.9% for the
heating time. For the temperature gap at the outer
surfaces of the LCD panel, a gain of 15.45% was
recorded. This percentage improves the quality of
the finished product and with the high productivity
of the process. In addition, it significantly reduces
the temperature gap and the consumed energy.
4 References
[1] G. Wang, G. Zhao, X. Wang, Experimental
research on the effects of cavity surface temperature
in rapid heat cycle molding process. International
Journal of Advanced Manufacturing Technology
2013, 68 (5-8), 1293-1310.
[2] G. Lucchetta, M. Fiorotto, P.F. Bariani,
Influence of rapid mold temperature variation on
surface topography replication and appearance of
injection-molded parts. CIRP Annals –
Manufacturing Technology 2012, 61 (1), 539-542.
[3] G. Lucchetta, M. Fiorotto, Influence of Rapid
Mould Temperature Variation on the Appearance of
Injection-Moulded Parts. Journal of Mechanical
Engineering 2013, 59 (11), 683-688.
[4] G. Wang, GQ. Zhao, H. Li, Research of thermal
response simulation and mold structure
optimization for rapid heat cycle molding
processes, respectively, with steam heating and
electric heating. Mater Des 2010; 31: 382–395.
[5] G. Wang, GQ. Zhao, H. Li, Analysis of thermal
cycling efficiency and optimal design of
heating/cooling systems for rapid heat cycle
injection molding process.Mater Des 2010; 31:
3426–3441.
[6] X.P. Li, M.X. Ma, “Optimal design of heating
channels for rapid heating cycle injection mold
based on response surface and genetic algorithm”,

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