m243 ch13

Dr.
Joseph Greene Copyright 2000 All Rights Reserved

1
Cooling
Chapter 13

Dr. Joseph Greene Copyright 2000 All Rights Reserved
2
Mold Cooling
Introduction
Factors which affect Mold Cooling
Laying Out Cooling Channels
Size and Number of Supply Lines
Coolant Requirements for a Mold

3
Introduction
Guidelines for mold cooling
Parameters that affect economical mold cooling
Plastic materials molded
Mold material
Molding machines
Cycle Time
Shape of product
Mold Cost
Anticipated lifespan of mold
Operators

4
Cool and Injection Mold
Molds shape hot, injected plastic into desired shape
Hot plastic cools in mold.
Mold is a heat exchanger where heat from plastic is
removed by the coolant flowing in mold channels.
Parts can be ejected when part is cooled down.
Mold and Injection Temperatures for some plastics

Plastic Inject Temp C Mold Temp C
PE 170-320 0-70
PS 200-250 0-60
Nylon 240-320 40-120
AcrStyr 230-260 50-80
PC 280-310 85-140
POM 180-230 70-130
PP 180-280 0-80
ABS 180-140 50-120
5
Cooling Factors
What affects Cooling of Mold?
Temperature increase (T) of coolant from in to out
Flow rate of coolant
Chemical composition & thermal conductivity of coolant
Thermal conductivity of mold parts
Temperature drop of plastic from injection to ejection
Runner system size and layout
Type of runner system (hot or cold)
Cooling channels layout and size
Return lines number and diameter
Cooling capacity of chiller
Mold close time and related cycle time

6
Coolant versus Plastic Temperatures
Coolant Temperature
Cooling medium is usually water, preferably conditioned
so as to minimize corrosion and scale
Antifreeze is added when temperatures are low or supply
lines are exposed to freezing temperatures.
Cooling is usually kept at or above 5C (40F)
Plastic Temperature
Heat is added to cool plastic granules so that they melt in
barrel and then flow as a liquid in mold at melt temp.
Heat is extracted from mold during total cycle time,
including opening, cooling, closing, and dead times
Faster cycle times leaves less time for cooling

7
Basic Principles
Heat, Temperature, and Energy
Energy is capacity to do work. Heat is one form of energy
Heat is energy in transit from a hot body to a cold body
Temperature is a property of a body that heat is applied
Heat is measured in calories or BTUs(British Thermal
Units)
1 calorie is the amount of required to raise the temperature of 1
gram of water by 1 degree C.
1 BTU is the amount of energy required to raise the
temperature of 1 pound of water 1 degree F
You raise the temperature from a low Temperature to a
high temperature by adding calories or BTUs

8
Basic Principles
Thermal Transfer
Heat can be transferred by mostly by conduction and
convection, and in rare cases radiation.
Conduction- the transfer of heat between two materials that are
in contact with each other and is proportional to the thermal
conductivity, k. Fouriers Law (Heat flux) Q/A = k (T
2
-T
1
)/(L
2
-L
1
)
Example, A pan on a hot plate will heat up while it is sitting on hot plate
and is dependent upon the thermal conductivity of the pan and plate. A
pan with high thermal conductivity (copper) will heat up faster than a
pan made of lower conductivity (glass).
Example, the hot plastic will heat up the mold due to conductivity of the
plastic and the mold material. Molds heat mostly due to conduction.
Convection- the transfer of heat between two materials that
have a fluid motion with at least one. Heat Flux = Q/A =
coolant velocity* k-coefficient * (T
2
-T
1
)/(L
2
-L
1
)
Example, A Fan will cool you off due to convection of air
Example, Molds are cooled mostly by convection of cooling water in
mold that removes heat from mold material.
9
Basic Principles
Thermal Transfer
Amount of heat flowing (calories) from one location to
another gets larger with
Larger Temperature difference in plastic hot to cold
Higher thermal conductivity material (Cu or BeCu)
Larger cross sectional area of part (Big parts = big heat flow)
In mold:
Heat from plastic flows into mold,
From mold to coolant,
From mold to platens and air
From coolant to chiller
10
Basic Principles
Thermal Transfer
Temperature Difference
Plastic from injection temp (high) to ejection temp (low)
Plastic from inside core temp (hot) to mold wall (low)
Cooling water from mold inlet (cold) to mold outlet (warmer)
Note: for most general purpose molds the temperature difference of
coolant from outlet of mold to inlet of mold should be less than 6C
Note: some production molds require 1 to 2 C temperature difference
Thermal Conductivity
Is a measure of the rate at which a material conducts heat from
a hot to cold.
Plastics have low thermal conductivity and can insulate a part if
the part is too thick and lengthen cooling times
Mold material thermal conductivities are in reference books.

11
Basic Principles
Thermal Transfer (Continued)
Heat Content
To raise temperature of the plastic a certain amount of energy is
required to melt it as well as to cool it from melt state.
Heat capacity of materials are unique like other properties, e.g. density.
Heat removal from the plastic takes place through the walls of
the cavity that is in contact with a coolant which takes away
heat back to the chiller where it is cooled.
Amount of heat required is dependent upon the amount of
plastic material in the mold and the type of plastic material.
Crystalline plastics require more energy to heat or cool than amorphous.
Amorphous regions heat or cool at a constant rate. Crystalline regions
require more energy during transition at the Tg.
The speed at which the plastic is cooled is dependent upon the
conductivity of the mold material, the plastic thermal, and the
coolant fluid.

12
Basic Principles Heat Transfer
Coolant Flow
Amount of heat removed is dependent upon the temperature difference
between the hot plastic and the cold coolant.
Various factors affect the flow of coolant.
Pressure drop of coolant in supply and return lines
Higher pressures provide higher flow and better heat transfer (70-85psi)
Cross sectional area of passages
Larger cross section = higher flow rate = higher heat transfer
Length of the coolant passages
Longer flow length of channels (more passes) = higher heat transfer
Viscosity of coolant
Lower viscosity = higher flow = better heat transfer
Amount of scale and rust in coolant channels
Lower scale and rust = better heat transfer
Reynolds number
Higher Re number = higher flow = better heat transfer
Turbulent flow is best with Re # > 4,000

13
Reynolds Number
Further experiments show that the three regions do
not depend solely on the flow rate, but on
Reynolds number = dimensionless combination of
the mean fluid velocity, density, viscosity, and diameter
Indicated relative importance of inertial (velocity) effects to
viscous effects.
Approx. Re Number Flow Region
< 2,000 Laminar
2,000 4,000 Transition
> 4,000 Turbulent
effects viscous
effects velocity D u
m
_
_
Re
Laminar
Flow
Turbulent
Flow
14
Basic Principles
Runner System
Hot and Cold runner systems produce different effects on
mold cooling
Cold runner
Plastic in runner is cooled the same way as the mold plates.
Cold runner is ejected with part.
Runners should be cooled to allow for it to eject.
Runners should be as small as possible for minimum cycle time
Hot runner
Plastic is kept hot from nozzle to cavities.
Hot manifold is kept heated and insulated from mold that is cooled
Temperature of the Mold Shoe
Purpose is to support and hold the cavities, cores, runners
Some of the heat travels to mold shoe which must be removed
Cavity and core should be at the same temperature

15
Basic Principles
Laying out Cooling Channels
Practical Recommendations
Length of Bore
Holes be drilled at least 6 mm away from other openings
Fig 13.10
Drill Size
Use standard, available drill sizes
Fitting Size
Use standard fitting sizes at the end of a bore. Use NPT and fittings
Pipe Threads and Fittings
Minimum distance from obstacles is governed by size of wrench
O-Ring fittings
Used instead of tapered pipe fittings
Less wedging action with O-ring so holes can be closer to walls
Less risk of leaking

16
Basic Principles
Distance of Cooling Channels
Distance from molding surface and from each other, Fig 13.12, are
needed to produce even surface temperatures on mold.
Distance between channels = B = 2.5-3.5Diameter of tube
Distance from surface = A= 0.8-1.5B
Note:If cooling channels are moved closer to surface, the cooling effect
on surface is greater and could have the the channels closer ut may
increase tool cost.

A
B
17
Basic Principles
Strength of Mold Material
Mold cavity must withstand pressures and forces create by plastic
during injection.
Can be 20,000 psi.
Safe permissible stresses in steel should be less than 10% of the yield
stress of the steel.
Efficiency of Cooling Channels: Fig 13.14B
The surface of the cooling surface can be more active due to:
More cooling channel surface near the molding surface
Only one side of the channel is in direct contact with the steel of the
mold cavity.
Separation between the mold plate and cavity can reduce contact
area by 50%.
Cooling lines should be in contact with the plastic, rather than in
adjoining plates.

18
Basic Principles
Series and Parallel Cooling
As coolant flows through channel it picks up heat from
the mold surface which is heated by the plastic.
Flows depend upon pressure differential between in and out
ports of cooling channels, length and diameter of channels.
Max temperature difference of 5C between in and out channels
Coolant flows in cooling lines which can be laid out in
series or parallel arrangement as follows.
Parallel arrangement (Fig 13.16)
Flow of coolant passes through all of the tubes from a common
manifold.
Series arrangement (Fig 13.15) Preferred
Flow of coolant passes through a series of tubes one after
another.

19
Basic Principles
Series and Parallel Cooling
Cooling efficiency depends not only on
the T between the mold and coolant, but also on
the amount of coolant flowing in channel (Turbulent is better)
The amount of coolant depends on the cross section of
the channel (for flow) and the surface area (for contact).
For round channels coolant depends upon d
2

Flow is cross sectional area time velocity = r
2
(velocity)
The amount of heat transfer between coolant and mold
walls depends on the surface area of the coolant channels
The area is proportional to diameter of tube.
Heat transfer = surface area time heat transfer coefficient= 2rh
Thus, doubling the size of the tubes has a 4 times increase in flow, but
the surface heat transfer only doubles
This is why you need many smaller tubes.

20
Basic Principles
Smaller size diameter tubes are more efficient for cooling
the molds.
Combination of parallel and series layout_Fig 13.17
Example,
Number of branches for N1, N2, N3 is 1, 2, and 6.
To calculate the size of diameters use the following equation:

where D1 is the input line diameter.
Combination of parallel & series are used in many molds
Plates may be all series cooled
Cores and cavities may be series or parallel cooled.
Depending upon
Quality of cooling required, space availability, strength of mold
material, number of cooling circuits available at machine, and number
of cooling circuits desired for simplicity of installation.

21
Basic Principles
Baffles in Plates
Cooling channels in plates are usually produced by
drilling and boring due to typical circular cross section.
To achieve flow path for coolant within the plate, the bores
must intersect.
Occurs in same plane of drilling, but is some cases offsets are required
from the center lines of the bores.
Important to make sure that the passage from one bore to the other does
not restrict the flow and that burrs from drilling can be removed.
Fig 13.18 shows typical end of a plate with plugs at the end of
the bores and baffles to direct flow.
Baffles are fastened to the rod with pins or screws.
Disadvantage of baffles and rods is that their fit in the bore must be
loose so that they can be assembled. Rust and sediment can cover bore.
Fig 13.19 shows different method for installing baffles which
eliminates need for removal. The baffle is threaded with plug.

22
Basic Principles
Runner and Cavity Plate in Three -Plate Molds
Cooling of this plate is a special case, as the plate
contains both the runners (with drops to cavities)
Important to cool runners and the drops as quickly as the
molded products so that they do not delay the ejection.
Most cases the drops are thicker than the walls of the molded
product and will cool slower.
Fig 13.24
Cross section of a three plate mold and location of cooling lines in both
runner and cavity retainer plates.
The runner must be cooled, especially around the drops.
Fig 35.
Cross section of a three-plate mold show cooling lines around cavity
and runners in one plate.
Cooling channels should be as close as practical toward the drops to
assure good cooling of the area

23
Divide molds into 3 basic groups according to shape
Flat products _ Fig 13.28A
Both sides of cavity and core are of approx. the same shape
Disks, records, trays, lids, test pieces, etc.
Cup-shaped products_ Fig 13.28B
Most molds. Cavity is a depression into which core enters
cups, pails, closures, casssettes, fascias, fenders, bumpers, etc.
Combination products_ Fig 13.28C
Include some products which for cooling purposes, combine
features of both these groups.
Spools, disks with hubs, door panels,

Layout and Sizing of Cooling Channels
in Mold Components that Contact
Molded Products
24
Compressibility and Shrinkage Review
Hot plastic (expanded) enters the cavity, and then after
pressure is released cools, it
Shrinks to return to its smaller, cold volume, and
Increases in size as the pressure on the plastic decreases.
Effect of shrinkage is the greater of these two influences
which results in the plastic cooling down and shrinking
on core.
Flat Products
Free to shrink in all directions.
If thickness is relatively small, and shrinkage and
compressibility are minor, then the cooling efficiency will be
the same on both sides and the length of product will reduce

25
Flat Products
Important that both sides of the product are equally well cooled.
Fig 13.29- Uneven cooling for flat product results in warpage
For thick parts
As part cools and shrinks on core , the cooling efficiency is
reduced on cavity side, since it has lost contact with cavity.
Smaller the core the more difficult the cooling becomes.
Cavity, Core, Insert, Gate Pad, and Stripper Cooling
Series Cooling_Fig 13.30A
Simple cooling and acceptable.
Series-Parallel Cooling_Fig 13.30B
Feeder and Return channels must be larger than the branched channels
to provide equal flow through each branch.
Requires more drilling, but cooling is better than series alone

26
Flat Products
Series-Parallel Cooling_Fig 13.30B
Often used for multi-cavity molds.
For very large number of cavities,
Feeder channels should be split to provide more even supply to the
branches_ Fig 13.31A
If feeder channels can be made large, Fig 13.31B is fine.
Cooling arrangement of the cavity & core side do not need to be same.
Easy to provide parallel cooling for cores, difficult for cavities.
Common approach is to use
Series or series-parallel cooling for cavities
Parallel or series-parallel cooling for cores.
OK because cooling of core is more important than cavity.

27
Flat Products
Parallel Cooling_Fig 13.30C: Typical cooling layout
All cavities are equally well cooled, provided branch channels are sized
so that the flow to each cavity (or core) is the same.
Most efficient but most costly.
First choice for high-speed, high-productivity molding ,e.g.,
thin disposable products,
Because of thin wall thickness, the heat must be removed equally fast
from both cavity and core to permit fast cycles.
Poorest cooled cavity will always control the length of the cycle time.
Parallel cooling is the most eficient
Restrictors in flow channels
Sometimes used to achieve equal flow through a number of parallel
branch channels.

28
Flat Products
Restrictors in flow channels
Sometimes used to achieve equal flow through a number of parallel
branch channels.
Can be avoided by properly sizing the flow channels in the first palce.
Sealing the passages from plate to plate.
O-rings at sealing points. Use standards from manufacturers for groove
dimensions and finishes.
Flat seals. O rings are located between flat surfaces
Fig13.33A_ Three examples of flat O-rings. A.preferred
arrangement, B tapered O-ring groove bottom to prevent seal from
slipping, and C. Poor arrangement wherein seal may slip into
channel.
They are compressed as the plates are joined.
Circumferential Seals: O rings located between cylindrical surfaces.

29
Flat Products: Cavities and Cores
Flat products have cavities and cores are virtually identical
Records, plates, test pieces, etc.
Heat must be removed equally between cavity and core.
Difficulties include:
Gate area is a source of additional heat input.
Ejector mechanism requires space that competes with cooling lines.
Mounting screws require sealing to prevent leaks.
Inserts and/or core pins often make it difficult to provide a
symmetrical, equal, and balanced cooling layout.
Localized heavy cross sections of the mold product should be
discussed with the product designer to discuss warpage isues.
Coolant supply to flat cavities and cores can be achieved in three ways.
Cooling channels in cavity block piped directly from outside.
Cooling channels to cavity block through backing plate.
Circular cooling groove around cavity through cavity retainer plate.
Fig 13.36 A, B, and C

30
Coolant Circuit Layouts in Flat Cavities
Mounting flat cavity blocks requires sufficient mounting
screws to hold the blocks solidly to the backing plate.
Screws should be located so that they will not seriously affect
the layout and the symmetry of the cooling channels.
If open channels are used (Fig 13.37 A) (Fig 13.37 B)
O rings are required and prevent coolant leaks through screw hole.
Common cooling circuits for mold cavities or cores
Concentric cooling circuit (Fig 13.38): Easily produced and cooling is
acceptable, but not as good as in spiral arrangements. (Fig 13.39)
Spiral cooling
Simple cavity block cooling layout for large flat product (Fig 13.40)
Cavity cooling for cup-shaped products (Fig 13.42)
Cavity inserts in a plate (cavity retainer plate)
Modular cavities mounted on backing plate

31
Core Cooling
Flat Products
Cooling method is same for cavities, but need to make room for
ejector pins which must pass through cooling lines.
Ejector pins must be sealed against coolant with O-rings, similar to
screws. (Fig 13.34)
Spot cooling is sometimes required, as in opposite gate.
Bubblers can be used with baffles. (Fig 13.52
Cup-shaped products
Small products
Choice of cooling is restricted and is often done with bubblers.
Some bubblers require baffles for better cooling.
Medium size products
Those whose core is too big to be cooled with a simple bubbler.
Depth of draw is generally one-half to double the diameter of the open
end.

32
Cup-shaped products
Medium size products
General rules
Area opposite the gate must always be properly cooled.
Cooling supply for the core should be directed first against the gate
area before being channeled to cool the rest of the core or use a
bubbler.
Provide adequate cooling for rest of the core.
Cores for Large Products
No clear distinction between medium and large products.
All methods used with medium-sized products can be applied to large
Large products typically have heavier walls and slower cycle times.
Coolant flows spirally in concentric grooves with connecting slots and
baffles from the center toward the rim of the product,
Venting is provided with vent pins
Many large cores are cross drilled for cooling and must have a bubbler
opposite the gate.

33
Gate Pad Cooling
Gate pad is an insert in cavity, surrounding the gate area.
Area is especially noted for cooling:
In hot runners, the plastic is kept hot up to the gate.
With open gates, the gate must freeze as the product cools down
If not properly cooled, gate may not freeze of and drool will result.
In valve gates, the tip of the valve where it shuts off from the gate must
be cooled so that the portion of the product opposite gate will have time
to solidify.
The valve pin is cooled by contact with the cooled gate pad.
In 3-plate molds, the heat content of heavy drop must be removed
quickly so that runners and drops care cold enough for ejection.

34
Gate Pad Cooling
Why have gate pad inserts?
If a witness line is permissible
Wear of the gate, especially in molding glass-filled systems.
Different materials can be selected for higher cooling rates.
Venting is easily done with a circular vent slot around gate.
Differential cooling is possible and eliminate separate gate pad
cooling circuits by properly designing the size of passages or
permanent restrictors.

35
Size and Number of Supply Lines (hoses)
Need to calculate the amount of coolant per hour is
required (Sec 13.6).
Amount of coolant per hour is proportional to amount of
plastic processed in the mold per hour.
Have manifold be apart of the mold plates to supply the
various channels of the core and cavity
Advantages
Minimize number of hose connections to one in and one out.
Mold operators can not alter the cooling flow pattern.
Automatic mold installation. Have fewer hoses.
Improved accessibility for air hoses and electrical connections.
Lower actual cost and upkeep since the number of small hoses and
joints is less.

36
Coolant Requirements for a Mold (heat exchanger)
Calculation of Heat Input
Estimated cycle time depends on
Shape of product, wall thickness, method of ejection, machine
characteristics (clamp speed, time, pressure), type of plastic
Estimate efficiency of cooling depends on:
Design and cooling layout, mold materials, temperatures of material,
mold, and plant.
Example,
Mass of plastic will be heated from Tr to Ti. Subsequently, in the mold,
it will be cooled from Ti to Te. Ti = Tinject and Te=Temp eject
Mass of plastic (Ms) shot size, per cycle equals Mass of each product
multiplied by number of cavities.
Ms = Mp x n
Mass per hour (Mh) = Mass of shot divided by Cycle time is
Mh = Ms (3600 sec/hr)/tc)

37
Specific Heat (Cp)
Ratio of the heat required to raise the temperature of a certain
mass of the given material by one degree C to that required to
raise the temperature of a similar mass of water by 1C.
Specific heat ratioof water is 1.
Specific heat ratio of most plastics is between 0.25 & 0.55. (Sec 22.11)
Can be expressed in either BTU/lb-F or cal/g-C
Example,
Product made from PS (Cp = 0,34) weighs 35 g and molded in 16-
cavity mold at 6 second cycle.
Shot size = 560 g
Shots/hour = 600
Mass molded/hour = 336,00 g/hour
Calories/hour = 114,240 cal/hour for 1C rise = heat = 478,300 J/hour
Total energy = 123 MJ/hour = 34.17kW

38
Cooling Requirements

Temperature of Cooling Water

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Joseph Greene Copyright 2000 All Rights Reserved

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